Building panels

ABSTRACT

A tough, water-proof building panel, made of fiber-reinforced polymer, is useful in making structural walls, ceilings, and floors of buildings. Upstanding such walls can have vertical and horizontal strengths sufficient to be used in place of concrete, as an engineered solution, both above grade and below-grade, including in severe weather conditions. Panels effectively have inner and outer layers, and structurally reinforcing members. Structurally-reinforcing members extend, typically as layer and/or stud, the full height of the wall panel, at spaced locations along the length of the panel. Spaces between the structurally reinforcing members are optionally filled with rigid thermally insulating foam. Optional reinforcing studs are attached to, or overlaid by, the inner layer, and extend inwardly into the building from what is otherwise the inner surface of the building panel. Panels can be made by e.g. assembling pre-fabricated blocks and/or webs, by evacuating a mold, and by pultrusion.

BACKGROUND OF THE INVENTION

This invention relates to building systems which largely replaceconcrete, whether ready-mix concrete or pre-fabricated concrete blocks,or other pre-fabricated concrete products, in construction projects. Ingeneral, the invention replaces the concrete in below-grade frost wallsand foundation walls, in above-grade walls, in concrete footers, and inpost pads. Such concrete structures are replaced, in the invention, withstructures based on resin-impregnated, fiber-based layers, as compositematerials, also known as fiber-reinforced polymer materials (FRP). Suchstructures optionally include insulating foam, and optionally includeregularly-spaced “studs”, especially in upright wall sections. Thus,with the exception of concrete flat work such as concrete floors, theconventional ready-mix concrete truck is not needed at the constructionsite.

In conventional foundation construction, first a concrete footer isformed and poured using ready-mix concrete. After the poured concretefooter has cured to a sufficient degree, such as a few days later,concrete forms, e.g. 4-8 feet high, are brought in, assembled on site,and erected on top of the footer. Ready-mix concrete is then poured,from a ready-mix truck, into the forms and allowed to set up and cure,to thus create the foundation walls, or a frost wall if no basement isplanned.

In the alternative, and still addressing conventional foundationconstruction, the upright portion of the foundation wall can be builtusing pre-fabricated concrete masonry units (cmu's) and mortar,typically supported by conventional poured concrete footers.

In yet another conventional type construction, the frost walls orfoundation walls are built using mortared concrete blocks.

In any event, in such conventional structures, as the concrete is beingfinished at the tops of the forms, or at the top course of concreteblocks, bolts or other hold-down anchors are partially embedded in thesetting-up concrete or mortar such that the anchors extend from the topof the foundation wall and, once the poured concrete, or mortar, has setup, such anchors serve as hold-down anchors, for example to mount a topplate to the top of the foundation wall, thus to anchor the overlyingbuilding structure to the foundation or frost wall. Once the concrete ina conventionally-poured foundation wall sets up, the forms are removed,e.g. 1-2 days after the ready-mix concrete is poured into the forms, anda wood, or wood-product, or other top plate is anchored to the top ofthe concrete foundation wall, using the anchors which are embedded inthe concrete at the top of the concrete foundation wall. A similarwaiting time is needed with a mortared concrete block wall, before thetop plate is anchored to the top of the so fabricated wall.

The above-noted poured concrete wall construction process, and concreteblock construction process, both require a substantial quantity ofconcrete materials, investment in forms, substantial on-site labor andseveral days of time to fabricate the building foundation on which theground floor of the building can then be erected. If construction isdone in winter in a northern climate, the concrete is typically heatedin order to facilitate curing of the concrete.

In addition, a resulting such concrete foundation wall is permeable towater and so must be water-proofed though, even after a conventionalwater-proofing coating has been applied to make the foundation wallwater-proof, water leakage through such concrete foundation wall,whether ready-mix wall or concrete block wall, is rather common.Further, a concrete wall is a good heat conductor, and thus should beinsulated to avoid heat loss by conduction through the concrete to thesoil or other fill which surrounds the building. However, the affect ofsuch insulation is limited because only relatively thin insulationmaterials are commonly used with underground concrete wall construction.

Yet further, if the level of the building inside the concrete wall is tobe inhabited, whether below grade, e.g. foundation wall, or above grade,then stud furring e.g. 2×4 studs or 2×6 studs are typically attached tothe concrete wall as a substrate which facilitates installation ofinsulation and utilities, and serves as a substrate for installing afinished interior wall surface such as sheet rock or paneling. Suchfurring takes up interior space inside the building as well as costingadditional time and money to install.

The overall time required to construct such building foundation can bereduced by fabricating concrete walls off-site and erecting thefabricated walls in place on site, using a crane. However, each suchwall element must be custom-designed, adding to the cost; and mechanicallifting equipment, e.g. the crane, must be brought to the constructionsite.

Getting foundation walls installed in a timely manner, to accommodatetimely delivery of constructed homes and other buildings to buyers, is asignificant issue in the construction business. There are many reasonswhy foundations are not installed in accord with a planned schedule. Asubstantial such problem is the weather. The weather in northernclimates can be below freezing for several months of the year, whichmakes it difficult to get foundations installed. In addition, installingquality concrete foundation walls requires skilled labor, as well asskilled subcontractors, including the subcontractors' skilled labor.

Another known method of constructing structural walls is the use ofInsulated Concrete Form (ICF) walls. In such construction, insulatedforms are erected on the footers, and receive ready-mix poured concrete.After curing, the outer portions of the forms are left as a layer ofthermal insulation between the concrete and at least one of the innerand outer surfaces of the resulting wall. Although ICF walls do offer arelatively higher level of thermal insulation than a conventionaluninsulated concrete wall, an ICF wall is typically more expensive thana plain concrete wall, and is more difficult to finish than a plainconcrete wall, whether finishing the insulated interior of the wall orthe insulated exterior of the wall.

Yet another alternative conventional foundation wall system isconstructed of wood which has been treated to inhibit decay, andcorresponding decomposition of the wood. Such treated wood is well knownand is conventionally available. Such foundation walls typically includeat least a bottom plate, and can be wrapped in plastic and then set onan aggregate stone footer. Wood foundations have a number of advantages,including enabling a manufacturer of such wood foundations to fabricatesections of such wall in the closed and controlled environment of amanufacturing facility, whereby selling and delivering such product isgenerally insensitive to weather conditions. Further, wood offersbeneficial speed in constructing a building.

The primary problem with wood foundations is that wood foundations arenot well received by the consuming public, as the public does notperceive quality in a building where wood is used in a below-gradeapplication.

There is a need, in the construction industry, for light weightstructural building panels, for example generally continuous wall panelsof any desired length up to a maximum length per panel, selectable inlength, in height, and in thickness, which structural building panelscan be used in applications where concrete is conventionally used inresidential, light commercial, and light industrial construction, andwhich structural building panels are strong enough to bear both thecompressive loads and the lateral loads which are typically imposed onsuch concrete walls in a building structure.

There is also a need for walls which have superior moisture and waterbarrier properties.

There is yet further a need for walls which can be installed so as to beready to support overlying building structure in a shorter period oftime.

There is still further a need for walls which can be installed at alower life cycle cost.

These and other needs are alleviated, or at least attenuated, by thenovel construction products and methods of the invention.

SUMMARY OF THE INVENTION

This invention is a tough, water-proof building system which provideswall, ceiling, and floor building panels. The walls have both verticalcompression-resistance strength, and horizontal bending-resistancestrength, sufficient that the wall system can be used in bothabove-ground and below-ground building wall structural applications,including applications where such wall systems are exposed to severewind and other weather, such as hurricanes, tornadoes, and the like.Such walls can replace concrete, and can be adequate to meetcorresponding required strength specifications for typical single-familyresidential, light commercial, and light industrial applications.

Similarly, ceilings and floors made with building panels of theinvention have vertical and horizontal loading capacities well able tosupport the loads typically imposed on ceilings and floors inresidential, light commercial, and light industrial construction.

A wall structure of the invention has an outer waterproof layer,comprised of reinforcing fibers embedded in polymeric resin, anddefining the outwardly-facing surface of the panel. At least onefiber-reinforced polymeric structurally-reinforcing member extends,typically as a layer, the full height of the erected wall panel, andextends from at or proximate the inner surface of the outer layer to alocation at or proximate an inner surface of the wall structure, atspaced locations along the length of the wall panel.

The inwardly-facing surface of the wall structure, considered in anorientation where a wall panel is installed as an upright wall in abuilding, can be formed by a separate structurally-reinforcing innerlayer of fiber-reinforced polymeric (FRP) material, whereby thereinforcing layer is entirely enclosed between the inner layer and theouter layer.

Any or all of the inner layer, the outer layer, and the reinforcinglayer can be thought of as fiber-reinforced resin layers or asresin-impregnated fiber layers. Either approach in materials descriptionrecognizes the structural contribution of both the fiber and the resinto the desired physical properties of the panels, and the benefit ofhaving both materials in the panel structure.

Optionally, a reinforcing stud is attached to, or overlaid by, the innerlayer, and extends inwardly into the building from what is otherwise theinner surface of the building panel/wall panel. Alternatively, the studcan originate at the outer layer, and extend into the building beyondwhat is otherwise the inner surface of the building panel.

The spaces between the inner-to-outer runs of the structurallyreinforcing member, and between the inner and outer layers, areoptionally filled with rigid insulating foam material such aspolyurethane foam or polystyrene foam, or polyisocyanurate foam.

Any of a wide variety of rigidifying, stiffening materials can be usedas the structurally-reinforcing member to provide stiffness, rigidity tothe structural building panel. Each such material has its own structuralcharacteristics which direct desired cross-section shapes of therespective materials. Relatively more advantageous materials haveinsulating “R” values of greater than 0.5, optionally greater than 10.

The structurally-reinforcing members are attached to, or form portionsof, both the outer layer and the inner layer of the structural buildingpanel, whether by cured resin bonding or by adhesive bonding, or byextrusion/pultrusion with the inner and outer layers, whereby thereinforcing elements of the structurally-reinforcing members, whichextend between the inner and outer layers of the panel, function in acapacity similar to the web of an I-beam, and inner and outer regions ofthe structurally reinforcing members function in capacities similar tothe functioning of flanges of such I-beam. The overall I-beam effectprovides, in an upstanding wall panel, or wall, both horizontal bendingstrength and vertical compressive strength, sufficient to support boththe vertical compressive loads, and the lateral side loads, for whichbuilding walls are designed, and provides such sufficient levels ofstrength in cross-sections which are no greater than the cross-sectionsof concrete walls which are conventionally used in such applications,while avoiding the drawbacks of concrete.

Building panels of the invention can be used in below-grade applicationssuch as in foundation walls and frost walls, in above-grade applicationssuch as building sidewalls, and in e.g. ceiling, roof, and floorapplications.

In a first family of embodiments, the invention comprehends aresin-based, fiber-reinforced polymeric structural building panel,designed and adapted to be used in constructing a building. The buildingpanel has a height defined between a top and a bottom of the buildingpanel when the building panel is in an upright use orientation. Thebuilding panel further has a length and a thickness, and comprises anouter fiber-reinforced polymeric layer, the outer layer defining anoutwardly-facing surface of the building panel when the building panelis being used in a building wall; an inner fiber-reinforced polymericlayer, the inner layer defining an inwardly-facing surface of thebuilding panel when the building panel is being used in a building wall;and a plurality of structurally-reinforcing members extending betweenthe top and the bottom of the building panel, and extending betweenlocations at or proximate the outer layer and locations at or proximatethe inner layer; the building panel further comprising t least one of(i) a top plate, or a bottom plate, or (ii) a plurality of studsextending inwardly of the inwardly-facing surface; or (iii) rigidinsulating foam elements extending between, and being insurface-to-surface contact with, respective ones of thestructurally-reinforcing members, the inner layer, and the outer layer,or the one or more structurally-reinforcing members comprisingfiber-reinforced polymeric members, or (vi) the building panel, in anupright use orientation, having a top-to-bottom crush resistancecapacity of at least about 4000 pounds per lineal foot.

In some embodiments, the inner layer and the outer layer compriseresin-impregnated fiberglass layers.

In some embodiments, the building panel further comprises at least oneof a wood top plate and a fiber-reinforced polymeric bottom plate,optionally a pultruded bottom plate and wherein such bottom plate is atleast about 0.18 inch thick.

In some embodiments, the building panel has a vertical crush resistanceof at least 6000 pounds per lineal foot.

In some embodiments, the building panel has a point horizontal loadingbending moment resistance of at least about pounds per square footbetween the top and the bottom.

In some embodiments, the inner layer, the outer layer, and thestructurally reinforcing members comprise fiber-reinforced polymericstructures, and the building panel comprises a plurality of studs,spaced from each other along the length of the building panel andextending generally between the top and the bottom, the studs extending,away from the inner layer and away from the outer layer in a commondirection.

In some embodiments, the building panel comprises a top plate, apultruded bottom plate, and a plurality of studs extending inwardly fromthe inwardly-facing surface and away from the outer layer, the studsbeing arranged generally parallel to each other and being spaced fromeach other, and extending from the inwardly-facing surface a distance ofabout 1 inch to about 6 inches.

In some embodiments, the building panel comprises rigid insulating foamelements extending between, and being in surface-to-surface contactwith, respective ones of the structurally-reinforcing members.

In some embodiments, the reinforcing members are comprised in a weavinglayer which weaves back and forth, as the structurally-reinforcingmembers, at crossings which extend across a distance which separates theinner layer and the outer layer, the crossings being spaced along thelength of the building panel, the weaving layer extending along at leastone of the inner layer and the outer layer between the crossings, andwherein first portions of the weaving layer form unitary structuralelements with second portions of at least one of the inner layer and theouter layer between the spaced crossings.

In some embodiments, the inner layer forms a unitary structural elementin combination with portions of the structurally reinforcing members.

In some embodiments, at least one of the inner layer and the outer layerhas a nominal thickness between about 0.03 inch thick and about 0.15inch thick.

In some embodiments, the crossings of such weaving layer are spaced fromeach other, along the length of the building panel, at distances ofabout 4 inches to about 24 inches.

In some embodiments, the building panel further comprises anchorbrackets associated with at least one of the top of the building paneland the bottom of the building panel, the anchor brackets supporting atop plate and/or a bottom plate from the inner layer.

In some embodiments, the building panel further comprises at least oneof a bottom plate mounted to the bottom of the building panel and a topplate mounted to the top of the building panel.

In some embodiments, a support bracket is mounted to the building panelin association with the top of the building panel, the support bracketcomprising a floor support panel adapted to support an edge of a flooradjacent the building panel, which edge overlies the floor supportpanel, and a brick support panel adapted to support bricks as anoutwardly disposed layer on a building in which the support bracket isused.

In some embodiments, the building panel further comprises rigidinsulating elements of closed cell foam having densities of about 1pound per cubic foot to about 12 pounds per cubic foot, optionally about2 pounds per cubic foot to about 8 pounds per cubic foot and fillingspaces between the inner layer and the outer layer, and betweenrespective ones of the structurally-reinforcing members.

In some embodiments, at least one of the inner layer and the outer layercomprises portions of multiple layer elements which overlap each otherin, at least in part, defining the respective inner layer or therespective outer layer.

In some embodiments, the one or more structurally-reinforcing memberscomprises upstanding structurally-reinforcing members when the buildingpanel is in an upright orientation, further comprisingtransversely-extending structurally-reinforcing members extendingbetween ones of the upstanding structurally-reinforcing members.

In some embodiments the transversely-extending structurally-reinforcingmembers and the upstanding structurally-reinforcing members collectivelydefine regular closed geometric shapes, which extend generallycontinuously between the inner layer and the outer layer.

In some embodiments, the inner layer, the outer layer, and thestructurally-reinforcing members are defined by a plurality offiber-reinforced layer elements and wherein a given such layer elementextends (i) from a first end thereof adjacent a first outwardly-facingside of a first insulating foam element along an outwardly-facingsurface of a second insulating foam element to a second side of thesecond insulating foam element, (ii) between the second side of thesecond insulating foam element and a first side of a third insulatingfoam element to inwardly-facing sides of the second and third insulatingfoam elements, and (iii) along the inwardly-facing side of the thirdinsulating foam element to an inwardly-facing side of a fourthinsulating foam element, and to a second end of the given layer elementadjacent the inwardly-facing side of the fourth insulating foam element.

In a second family of embodiments, the invention comprehends aresin-based, fiber-reinforced composite structural building panel,having a height defined when the building panel is in an upright useorientation, a length, and a thickness. The structural building panelcomprising an outer fiber-reinforced polymeric layer, the outer layerdefining an outwardly facing surface of the building panel when thebuilding panel is being used in a building wall; an innerfiber-reinforced polymeric layer, the inner layer defining aninwardly-facing surface of the building panel when the building panel isbeing used in a building wall, the inner layer and the outer layerdefining a general thickness of the building panel; a plurality ofstructurally-reinforcing members extending between the top and thebottom of the structural building panel, and extending from locations ator proximate the outer layer to locations at or proximate the innerlayer; rigid insulating foam elements in the structural building panel,extending between, and being in surface-to-surface contact with,respective ones of the structurally reinforcing members; and reinforcingstuds between the rigid insulating foam elements and the inner layer,the reinforcing studs being so dimensioned that the thickness of thebuilding panel at the reinforcing studs extends inwardly, as into abuilding in which the building panel is installed, from the innermostextent of the general thickness.

In a third family of embodiments, the invention comprehends aresin-based fiber-reinforced composite structural building panel, havinga height defined when the building panel is in an upright useorientation, a length, and a thickness. The structural building panelcomprises an outer fiber-reinforced polymeric layer, the outer layerdefining an outwardly-facing surface of the building panel when thebuilding panel is being used in a building wall; an innerfiber-reinforced polymeric layer, the inner layer defining aninwardly-facing surface of the building panel when the building panel isbeing used in a building wall; rigid insulating foam elements in thestructural building panel, (i) a first set of the foam elements havinglengths thereof extending along the height of the building panel, widthsthereof extending along the length of the building panel, andthicknesses thereof, less than the respective widths, extending alongthe thickness of the building panel, and (ii) a second set of the foamelements having lengths thereof extending along the height of thebuilding panel, widths thereof extending along the thickness of thebuilding panel, and thicknesses thereof, less than the respectivewidths, extending along the length of the building panel, the widths ofthe second set of the foam elements being greater than the thickness ofthe first set of the foam elements, ones of the second set of foamelements being spaced from each other by ones of the first set of foamelements.

In some embodiments, the inner layer extends over inner surfaces of thefirst set of foam elements and over inner surfaces of the second set offoam elements such that both the first set of foam elements and thesecond set of foam elements are disposed between the inner layer and theouter layer.

In some embodiments, the inner layer extends inwardly into suchbuilding, from adjacent a foam element of the first set to an inner-mostportion of a foam element of the second set, a distance of about 3inches to about 6 inches.

In some embodiments, foam elements of at least one of the first andsecond sets of foam elements are wrapped in resin-impregnated fibrouslayers.

In some embodiments, the wrapping layers have nominal thicknesses ofbetween about 0.03 inch thick and about 0.15 inch thick.

In a fourth family of embodiments, the invention comprehends aresin-based, fiber-reinforced polymeric composite structural buildingpanel designed and adapted to be used in constructing a building, thebuilding panel having a height defined between a top and a bottom of thebuilding panel when the building panel is in upright use orientation, alength, and a thickness, the structural building panel comprising afiber-reinforced pultruded structure. The pultruded structure comprisesan outer fiber-reinforced polymeric layer defining an outwardly-facingsurface of the building panel when the building panel is being used in aload-bearing building wall; an inner fiber-reinforced polymeric layerdefining an inwardly-facing surface of the building panel when thebuilding panel is being used in a load-bearing building wall; and aplurality of bridging members spaced along the length of the buildingpanel and bridging between the inner layer and the outer layer, thebuilding panel in upright use orientation having a vertical crushresistance capacity of at least about 2000 pounds per lineal foot lengthof the building panel.

In some embodiments, the building panel further comprises a plurality ofstuds extending inwardly from the inner surface and away from the outerlayer, between the top and the bottom of the building panel, the studsbeing spaced from each other along the length of the building panel.

In some embodiments, the building panel further comprises a top plate atthe top of the building panel and a bottom plate at the bottom of thebuilding panel.

In some embodiments, the studs are integral elements of the pultrudedstructure.

In some embodiments, the building panel has a vertical crush resistancecapacity of at least of at least about 4000 pounds per lineal footlength and a point horizontal bending resistance of at least about 155pounds per square foot between the top and the bottom of the buildingpanel.

In a fifth family of embodiments, the invention comprehends aresin-based, fiber-reinforced polymeric composite structural buildingpanel designed and adapted to be used in constructing a building. Thebuilding panel has a height defined between a top and a bottom of thebuilding panel when the building panel is in an upright orientation, alength, and a thickness, and comprises a first set of fiber-reinforcedpultruded blocks having lengths thereof extending along the height ofthe building panel, widths of the first set of blocks extending alongthe length of the building panel, and thicknesses of the first set ofblocks, being less than the respective widths, extending along thethickness of the building panel; a second set of fiber-reinforcedpultruded blocks having end walls, and legs extending between the endwalls, and lengths of the pultruded blocks extending along the height ofthe building panel, widths of the second set of blocks extending alongthe thickness of the building panel, and thicknesses of the second setof blocks, less than the respective widths of the second set of blocks,extending along the length of the building panel, the widths of thesecond set of pultruded blocks being greater than the thicknesses of thefirst set of pultruded blocks, ones of the second set of pultrudedblocks being spaced from each other by ones of the first set ofpultruded blocks, the pultruded blocks of the first and second sets ofpultruded blocks being in abutting relationship with each other anddefining a generally continuous outer surface of such assemblage of suchpultruded blocks, and an inner surface of such assemblage of suchpultruded blocks: and an outer fiber-reinforced polymeric layer mountedto, or adjacent, the first and second sets of pultruded blocks at oradjacent the generally continuous outer surface, so as to bridge betweenrespective ones of the pultruded blocks.

In some embodiment, the building panel, in an upright use orientation,has a vertical crush resistance capacity of at least about 4000 poundsper lineal foot length of the building panel.

In some embodiments, the building panel further comprises a top plate atthe top of the building panel and a bottom plate at the bottom of thebuilding panel.

In some embodiments, the pultruded blocks of the second set comprising areinforcing web displaced from both said end walls and extending betweenthe first and second legs.

In some embodiments, the building panel further comprises an innerfiber-reinforced polymeric layer mounted over the first and second setsof pultruded blocks so as to consolidate the pultruded blocks of thefirst and second sets to each other at the inner surface of the buildingpanel.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a representative pictorial view, with parts removed, of abuilding foundation wall fabricated using building system structures ofthe invention.

FIG. 2 is a fragmented interior view of a section of one of theupstanding wall structures shown in FIG. 1.

FIG. 3 is an elevation-view cross-section of the upstanding wallstructure taken at 3-3 of FIG. 1.

FIG. 4 is an outside elevation representation of the upstanding wallstructure of FIG. 3.

FIG. 5 is a plan view of an upstanding wall section of FIG. 1.

FIG. 6 is a plan-view cross-section of a portion of the wall structuretaken at 5-5 of FIG. 2.

FIG. 7 is a plan-view cross-section of a portion of a foundation wallaccording to a second embodiment of the invention.

FIG. 8 is an enlarged plan-view cross-section of a portion of thefoundation wall structure of FIG. 7.

FIG. 9 is an elevation view cross-section of the foundation wallstructure illustrated in FIGS. 7 and 8.

FIG. 9A is an elevation view cross-section as in FIG. 9, illustrating adifferent arrangement for supporting an overlying floor.

FIG. 9B is an enlarged view of a top portion of the structure shown inFIG. 9A.

FIG. 10 is a fragmentary pictorial view showing a basement support padof the invention, supporting a conventional support post which supportsan I-beam as in a below-grade basement location.

FIG. 10A is a cross-section of a layered support pad illustrated in FIG.10, shown on an underlying rock or earth support base.

FIG. 10B is a cross-section of a pultruded support pad illustrated inFIG. 10, shown on an underlying rock or earth support base.

FIG. 11 is a pictorial view of a square resin-fiber composite supportpost, and resin-fiber composite cap, of the invention, supported by asquare resin-fiber composite support pad of the invention.

FIG. 12 is a pictorial view of a square resin-fiber composite supportpost, and resin-fiber composite cap, of the invention, supported by asquare resin-fiber composite, upwardly-tapered support pad of theinvention.

FIG. 13 is a pictorial view of a round resin-fiber composite supportpost, and resin-fiber composite cap, of the invention, supported by acircular resin-fiber composite support pad of the invention.

FIG. 14 is a pictorial view of a round resin-fiber composite supportpost, and resin-fiber composite cap, of the invention, supported by acircular, upwardly-tapered resin-fiber composite support pad of theinvention.

FIG. 15 is a pictorial line rendering of a resin-fiber composite supportbracket of the invention, which may be mounted to the top of afoundation wall of the invention as illustrated in FIG. 9.

FIG. 16 is a pictorial line rendering of one embodiment of a resin-fibercomposite channel stud of the invention, which stud can be incorporatedinto a wall panel of the invention as illustrated in FIGS. 7-9.

FIGS. 16A and 16B are pictorial line rendering of second and thirdembodiments of resin-fiber composite channel studs which can beincorporated into wall panels of the invention.

FIG. 17 is a pictorial line rendering of a resin-fiber composite “H”connector of the invention, which is used to connect first and secondwall sections in a straight line.

FIG. 18 is a pictorial line rendering of a resin-fiber compositefixed-angle bracket of the invention which can be used on inner and/orouter surfaces of a wall section, connecting first and second wallsections at a perpendicular angle.

FIG. 19 is a pictorial line rendering of a resin-fiber compositeadjustable-angle bracket of the invention, for inner and outer wallsurface connections, and which is adjustable regarding the angle atwhich the respective panels of the bracket meet at a line of joinder.

FIGS. 20 and 20A are pictorial views of resin-fiber composite plateanchor brackets useful proximate the tops and bottoms of wall panels ofthe invention e.g. for anchoring a top plate and/or a bottom plate tothe wall panel.

FIG. 21 is a pictorial line rendering of a resin-fiber composite floorand garage apron ledge bracket of the invention.

FIG. 22 is a plan view cross-section of a joint in a wall of theinvention, joining first and second building panels of the inventionusing an “H” connector of FIG. 17.

FIG. 23 is a plan view cross-section of a joint on a wall of theinvention, joining first and second building panels of the invention ata 90 degree corner, using first and second fixed-angle bracketconnectors of FIG. 18.

FIG. 24 is a plan view cross-section of a joint on a wall of theinvention, joining first and second building panels of the invention ata 90 degree corner, using a single fixed-angle corner bracket to providecontrol both on the inner surface of the wall and on the outer surfaceof the wall.

FIG. 25 is a representative elevation view of an exemplary process ofthe invention which can be used to make building panels of the inventionsuch as those illustrated in FIG. 8.

FIG. 26 shows a plan view cross-section of an embodiment of buildingpanels of the invention wherein channel studs are between the innerlayer and the foam blocks.

FIG. 27 is a representative elevation view of an exemplary process ofthe invention which can be used to make building panels of the inventionsuch as those illustrated in FIG. 26.

FIG. 28 shows a plan view cross-section of an upstanding building panelof the invention wherein foam blocks are enclosed in pre-wrapped andcured layers of fiberglass/resin composites before being joined to theinner and outer layers.

FIG. 29 illustrates a fragmentary end elevation view of a building panelpre-form in a vacuum infusion process being used to fabricate a buildingpanel of the invention using pre-wrapped foam blocks as in FIG. 28 andan overlying inner layer as illustrated in FIG. 26.

FIG. 30 shows a plan view cross-section of another embodiment of anupstanding building panel of the invention wherein pre-wrapped foamblocks provide the reinforcement structure of the reinforcing member.

FIG. 31 shows a plan view cross-section of yet another embodiment of anupstanding building panel of the invention.

FIG. 32 shows a plan view cross-section of a first embodiment ofupstanding uninsulated building panels of the invention.

FIG. 33 shows a plan view cross-section of a second embodiment ofupstanding uninsulated building panels of the invention.

FIG. 34 shows a plan view cross-section of a third embodiment ofupstanding uninsulated building panels of the invention.

FIG. 34A shows a plan view cross-section of fragmentary portions offirst and second upstanding building panels, illustrating edgestructures of the two panels.

FIG. 34B shows plan view cross-sections of first and second upstandingbuilding panels illustrating edge structures, including integral studs.

FIG. 35 shows a cross-section of a building panel of the inventionincorporating the hollow studs of FIG. 16B.

FIG. 36 shows a cross-section of a building panel of the inventionassembled from elongate pultrusions, including pultruded studs, allgenerally rectangular in cross-section.

FIG. 37 illustrates a vacuum molding process for making a building panelof the invention having studs extending inwardly from the main innersurface of the building panel.

FIG. 38 shows a cross-section of a building panel incorporating studsillustrated in FIG. 16B and using the process of FIG. 37.

FIG. 39 shows a side elevation view, with parts cut away of a portion ofa fourth uninsulated building panel of the invention.

The invention is not limited in its application to the details ofconstruction, or to the arrangement of the components set forth in thefollowing description or illustrated in the drawings. The invention iscapable of other embodiments or of being practiced or carried out invarious other ways. Also, it is to be understood that the terminologyand phraseology employed herein is for purpose of description andillustration and should not be regarded as limiting. Like referencenumerals are used to indicate like components.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

Referring to FIG. 1, a plurality of interior and exterior foundationwalls 10 collectively define the foundation 12 of a building. Eachfoundation wall 10 is defined by one or more foundation wall panels 14.In the illustration, each foundation wall panel 14 includes a bottomplate 16, an upstanding wall section 18, and a top plate 20. Eachupstanding wall section 18 includes a main-run wall section 22, anduprightly-oriented reinforcing studs 23 affixed to, or integral with,the main-run wall section, regularly spaced along the length of the wallsection, and extending inwardly of the inner surface of the main runwall section. In the embodiment illustrated in FIG. 1, anchoringwedge-shaped brackets 24 are mounted to the studs at the tops andbottoms of the wall section, thus to assist in anchoring the bottomplate and the top plate, and/or any other attachment, to the main runportion of the upstanding wall section.

As illustrated in FIG. 1, conventional e.g. steel I-beams 26 are mountedto the wall sections, as needed, to support spans of overlying floors.Such steel I-beam can be supported at one or more locations along thespan of the I-beam, as needed, by either conventional e.g. steel posts,or by resin-fiber composite posts 28 of the invention (FIGS. 1 and 10)and/or resin-fiber composite pads 30 (FIGS. 1 and 10) of the invention.Additional support posts can be employed at or adjacent the ends of theI-beams as needed to satisfy specific, individual load-bearingrequirements of the building design. Fiberglass-reinforced brackets, orsolid reinforcing studs 23 (FIGS. 5-6) or hollow channel studs 123(FIGS. 7-9 and 16) or conventional e.g. steel brackets, can be used toattach the I-beams to respective panels of the foundation wall usinge.g. conventional steel bolts. Studs 23, are cut off, as needed, tosupport the I-beam at the desired height. Multiple studs can be usedside-by-side, as needed, to provide the desired load-bearing capacity.

Referring now to FIGS. 3, 5, and 6, the main run wall section 22 isgenerally defined between the inner surface and the outer surface of thewall panel, without considering the thickness at stud 23. The main runwall section thus generally includes a foam core, and the inner 34 andouter 36 layers of fiberglass-reinforced polymer (FRP), otherwise knownas fiberglass sheets or fiberglass layers. The foam core can be foamedin place thermally insulating material between pre-fabricated inner andouter layers, or can be made from pre-fabricated blocks 32 of thermallyinsulating foam material, which blocks are assembled, e.g. by usingadhesive or curable resin, with the remaining elements of the respectivewall panel as described in further detail hereinafter. Bottom plate 16and top plate 20 can be secured to the main run section with the supportof wedge-shaped brackets 24 (FIG. 2), or other supporting bracketstructure, optionally in combination with adhesive or additional curablepolymeric resin. The selection of adhesive depends on the selection ofthe material from which the top plate is made, as well as the specificmaterial which forms the respective face of the wall panel, and thematerial from which bracket 24 is made. An exemplary adhesive isPro-Series QB-300 Multi-Purpose Adhesive, available from OSI SealantCompany, Mentor, Ohio. Such adhesive can be used as desired to securevarious elements of the building panel assembly to each other.

The foam core layer is of sufficient density, rigidity, and polymerselection to fix the positions of the fiber-reinforced polymer layers intheir respective positions as illustrated. Thus, in the embodimentsillustrated in FIGS. 3, 5, and 6, the rigidity of the foam contributessignificantly to the dimensional stability of building panel 14. Inaddition, the foam provides substantial thermal insulation between theinwardly-facing surface of the wall and the outwardly-facing surface ofthe wall.

Bottom plate 16 can be a fiber-reinforced, e.g. fiberglass-reinforced,polymeric structural member, of such dimensions as to be sufficientlyrigid, and with sufficient strength, to support both the foundation walland the overlying building superstructure, from an underlying fabricatedbase defined by e.g. a settled bed 53 (FIG. 9) of stone aggregate, froman underlying fabricated base comprising a concrete footer 55 (FIG. 3),or from other suitable underlying fabricated supporting base. Thespecific structural requirements of bottom plate 16 depend on the loadsto be applied.

A pultruded fiber-reinforced product e.g. 0.075 inch (1.9 mm) to about0.5 inch (13 mm) thick has been found to be satisfactory as the bottomplate for general-purpose and typical single-family residential, lightcommercial, and light industrial construction.

The bottom plate can be attached to the upstanding wall section, andoptional support brackets 24, by adhesive, by curable resin such as thatused in the wall panel, by steel bolts which extend through an uprightleg of the bottom plate e.g. adjacent the outer surface of theupstanding wall section and through the adjacent portion of theupstanding wall section, or by a combination of metal anchors andadhesive and/or resin or by other attachment mechanism. In any event,the bottom plate, when attached to the upstanding wall section, issufficiently wide, thick, dense, and rigid, to provide effectivecompression and bending support, thus to support the foundation wallfrom the underlying soil and/or rock and/or stone, or other natural basealbeit typically through a fabricated footing.

The bottom plate typically extends laterally inwardly into the buildingbeyond the primary surface of the inner layer by a distancecorresponding to at least the maximum thickness of the building panelwhich includes stud 23, thus to present a suitably-sized bearing surfaceto the underlying support base whereby the overlying load can be borneby the underlying support base without causing substantial movement inthe underlying support base of soil, stone, or rock. In the alternative,the bottom plate can extend outwardly from the building panel, away fromthe building, to provide the recited suitably-sized bearing surface, orcan extend both inwardly and outwardly from the building panel.

The top plate can be made of wrapped layers of fiberglass, can be apultruded resin-fiber composite, can be conventional wood, or amanufactured wood product, or other conventional construction material,each such structure being sufficiently wide and thick to provide asupport surface, interfacing with the underlying upstanding wallsection, and from which the overlying superstructure of the building canbe supported. The top plate can conveniently be made from conventionalwood building materials whereby overlying building structures can beconventionally attached to the underlying foundation wall structure atthe building site by use of conventional fasteners, conventionallyattached to the top plate.

The combination of the inner and outer fiberglass layers 34, 36, and thereinforcing studs 23, for example wood 2×4's, 2×6's, as illustrated inFIG. 6, is sufficiently strong to withstand the inwardly-directedlateral, e.g. bending, forces which are imposed on a foundation wall bythe ground, or on above-ground walls by wind loads, both imposed fromoutside the building.

A suitable illustrative footer can be fabricated from aggregate stone,illustrated as 53 in FIG. 9 or concrete as illustrated at 55 in FIG. 3.A suitable aggregate stone has a size which passes through a 1 inch meshand does not pass through a ¾ inch mesh.

Referring to FIGS. 1, 3, and 9, once the foundation wall 10 is in placeas illustrated in FIG. 1, on a suitable footer (53, 55), a conventionalready-mix concrete slab floor 38 is poured. The concrete slab floorextends over, and thus overlies, that portion of the bottom plate 16which extends inwardly from any of the inner surfaces of the wallpanels, including both the main run wall section and studs 23. Namely,the concrete slab floor extends to, and abuts against, the innersurfaces of the respective upstanding wall sections 18. Accordingly,once the concrete slab floor is cured, inwardly-directed lateral forces,imposed by the ground outside the building, at the bottom of the wall,and taken in a direction aligned with the width of bottom plate 16, areresisted, opposed, nullified, by the structural e.g.lateral/side-to-side compressive strength of the concrete floor slab 38in support of foundation wall 10, as the edge of the slab abuts theinner surface of the foundation wall. Thus, inwardly-directed lateralforces which are imposed on the foundation wall adjacent bottom plate 16are ultimately resisted, and absorbed, by slab 38.

Inwardly-directed lateral forces which are imposed on the foundationwall at or adjacent top plate 20 are transferred to main floor 40 of thebuilding (FIGS. 3, 9, and 9A) e.g. by conventional mechanical fastenersand standard construction techniques which mechanically attach the mainfloor 40 and the foundation wall 10 to each other, or otherwise causethe main floor and the foundation to act together cooperatively.

Still referring to the main run wall section 22 (FIGS. 1, 3, and 6), andconsidering the structural environment of typical 1-story and 2-storyresidential construction, and where foam blocks 32 provide substantialcontributions to dimensional stability of the panel, the inner 34 andouter 36 fiberglass-reinforced layers are e.g. between about 0.75 mm andabout 3.8 mm (between about 0.03 inch and about 0.15 inch) thick.Thicknesses of the inner 34 and outer 36 layers are generally constantbetween respective ones of the reinforcing studs 23. The outer layer 36can be e.g. ribbed to enhance the ability of the wall to withstand theimposition of laterally-directed loads on the wall.

In the embodiments illustrated in FIGS. 1-6, studs 23 run the fullheight of the main wall section, and extend from inner surface 42 ofouter fiberglass layer 36, or the inner surface 52 of the innerfiberglass layer 34, inwardly and/or outwardly, a desired distance so asto provide the desired level of structural strength to wall panel 14. Inthe embodiments illustrated in FIGS. 1-6, the inner fiberglass layer 34is wrapped around the inwardly-facing surface 44 of the stud. Thewrapping of the fiberglass layer over the stud as illustrated in e.g.FIG. 6 provides a waterproof coating to a wood stud, e.g., withoutlimitation, a 2×4 stud, a 2×6 stud, a 2×8 stud or other dimension stud,so as to make the stud waterproof and insect proof. At the same time,the fiberglass layer wrap incorporates the stud into the unity of thestructure of the main wall section, whereby the bending resistancestrength of the stud contributes significantly to the overall bendingresistance strength of the assembly which defines the main run wallsection. Thus, studs 23 function as reinforcing members in wall panel14.

Compared to e.g. a 2.0 inch thick wall section, 8 feet in height, havingno reinforcing member, a corresponding wall which incorporates 2×4 studson 24 inch centers, wrapped on 3 sides by the inner layer asillustrated, exhibits about 25% increased bending resistance. Suchbending resistance is measured by applying a linear load which runs thelength of the wall panel at mid-height of the wall panel, and which loadis opposed by linear opposing blocking of corresponding lengths at thetop and bottom of the wall panel.

Referring to FIG. 6, in designing the main run wall section, both thelateral strength of an upstanding such wall section, and the compressivestrength of such wall section, can be reinforced as desired with e.g.“T” section reinforcements 46, or the like, which typically extend thefull height of the main run wall section. A given “T” sectionreinforcement has a flange 47 which extends generally parallel to outerlayer 36 and a web 49 which extends transverse to, generallyperpendicular to, outer layer 36. Web 49 typically extends across atleast half of the distance between the inner layer and the outer layer.“T” section reinforcements 46 can be made of any desired material whichcan contribute significantly to the structural strength of the wallsection. Typical such “T” section reinforcements can be steel,structural fiber reinforced polymer compositions such asresin-impregnated fiberglass structures or fiberglass-reinforcedpultrusions, or the like.

Flange 47 of the “T” section can be positioned against either outerlayer 36 as shown, or against inner layer 34. In either case, web 49extends inwardly across the thickness of the wall panel from the innersurface of the respective inner or outer layer. The surface of flange47, which faces the inner surface of the respective inner or outerlayer, is bonded, e.g. adhesively bonded, to the respective innersurface of the inner or outer layer. As adhesive, there can be mentionedrespective known construction adhesives. In some instances, the curableresin which is used in making the respective inner or outer layer isalso effective to secure the “T” section flange 47 to the respectiveinner or outer layer. Where the “T” section is placed against outerlayer 36, the “T” section can receive fasteners which attach additionallayers, such as siding, to the building outwardly of the outer surfaceof the wall panel.

In place of “T” section reinforcements, a wide variety of other elongatestructural constructs 46 can be embedded in the interior of the wallpanel. As other cross-section constructs, there can be mentioned, forexample and without limitation, cross-section profiles which representelongate perpendicular-angle 2-leg constructs e.g. eliminating half ofthe flange 47 shown in FIG. 6, elongate square tubes, elongate roundtubes, “H” section structures, “U”-section structures, “I” sectionstructures, and the like. Such construct can comprise multiple webs 49spaced along the length of the panel, and connected to one or moreflanges 47.

Typically, the number of such structural constructs 46 is no greaterthan the number of reinforcing studs 23, or the like which run the fullthickness of the main run wall section.

As desired, the “T” section or other structural constructs 46 can beomitted, whereby the resistance to e.g. gravitational compressive forcesand lateral forces, on the wall panel are derived largely from inner andouter layers 34, 36, and reinforcing members/studs 23 and whereinattachment fasteners are directed to stud 23.

FIG. 6 illustrates in dashed outline a wedge-shaped stud reinforcementmade of e.g. a resin-fiber composite. Such wedge-shaped reinforcementscan be added to the structure to further bolster lateral strength of thewall panel, at studs 23.

Studs 23 can be conventional wood studs as illustrated in FIG. 6, or canbe made by wrapping e.g. concentric layers of e.g. resin-impregnatedfiberglass sheet on itself until the desired cross-sectional shape isobtained. In the alternative, studs can be fiber-reinforced pultrudedstructures, either hollow structures or solid structures, namely anyelongate structural profile which provides desired structural andspacial properties.

Still referring to FIGS. 1-6, in general, the inner and outer layers ofthe wall section are fiberglass-reinforced resin sheets, full height andfull length of the wall section. The inner and outer layers 34, 36 aree.g. about 0.075 mm to about 3.8 mm thick, optionally about 0.75 mm toabout 2.5 mm thick. The blocks 32 of foam fill the entirety of the spacebetween the inner and outer layers 34, 36, except at the studs, wherethe studs typically fill the entire space, e.g. the full thickness ofthe wall section between the inner and outer layers, with the foamfilling all other space between layers 34 and 36.

Wall section thickness “T” (FIG. 8), in the main-run wall section isdefined without respect to the dimensions of studs 23 or 123, andgenerally stops at the surface 25 of what is later defined herein asspace 131. Thickness “T” can be as little as about 2 inches between theinner and outer surfaces of the wall, to as much as about 8 inches ormore, as measured between the outer surface of layer 34 and the outersurface of layer 36, and ignoring studs 23 for purposes of definingthickness “T”. Typical wall thickness is about 3 inches to about 6inches.

The top plate and bottom plate can be conventional e.g. wood materials,with suitable waterproofing as appropriate for the intended use. Inorder to avoid issues of moisture contact with wood, typically thebottom plate is a fiberglass-reinforced resinous composite, ofsufficient thickness and rigidity to provide the level of weight bearingcapacity anticipated as being necessary, for supporting the structure tobe supported.

As used herein, all fiberglass/resin composite structures, such asbottom plate 16, top plate 20, studs 23, and the like, can be fabricatedusing known techniques of dry or pre-impregnated fiberglass blanketmanipulation and construction, and resin impregnation of such materials,chop spray processes, vacuum infusion processes, pultrusion, or otherknown processes for making fiber-reinforced composites, in order to makethe desired 3-dimensional shapes. Such techniques can be used, forexample, to make bottom plate 16, to make studs 23, the wedge-shapedstud extensions illustrated in dashed outline FIG. 6, or wedge-shapedbrackets 24, and the like.

Structural building panels of the invention can be manufactured in anyof the standard dimensional sizes, as well as in a variety of other sizecombinations desired for a particular building project. Thus, forexample and without limitation, such panels can have heights of about 4feet, which accommodates use of the panels in 4-foot frost walls. Heightof about 9 feet accommodates use of the panels in standard-heightbasement walls and standard-height above-grade walls.

Thickness of the panels typically ranges from about 3 inches nominalthickness to about 8 inches nominal thickness. Studs described elsewhereherein can extend inwardly from such nominal dimensions. At least 3inches is typically desired in order to obtain necessary bendingresistance, as well as desired thermal insulation properties. However,additional bending resistance can be obtained through the use of studswhich extend inwardly from the nominal thickness. Further, additionalthermal insulation properties can be obtained by adding conventionalinsulation material between studs at the inner surface of the panel.

Typically, thickness greater than 8 inches is not needed in order tosatisfy structural demands of thermal insulation demands. However, insome instances, where extraordinary thermal or structural demands are tobe imposed on the building panels, then thickness greater than 8 inchesis contemplated.

Lengths of the panels is limited only by transportation limitations. Forexample, such panels can be as long as the length of the truck bed whichwill transport the panels to the construction site. Thus, length isgenerally limited to about 40 feet, but can be longer as desired wheresuitable transport is available. However, since an advantage of thepanels is limited weight such that the panels can be installed belowgrade and at grade level without use of a crane, length is in someembodiments limited to lengths which can readily be handled by manuallifting. Thus, lengths are typically no more than about 40 feet based onweight which can be accepted for manual lifting of the panels.

On the other hand, where a crane is to be used, and where suitabletransportation is available, the panels can be as long as desired forthe purpose intended.

Structural building panels of the invention provide a number ofadvantages. For example, the structural building panels can bemanufactured in a continuous length, and but for shipping, to anydesired length, which may be a generic length, for example 10 feet, or20 feet, or 40 feet, or whatever length or lengths is or are desired.The length needed for a particular portion of a building wall can be cutfrom a generic-length building panel, at the construction site, to meetspecific needs, or can be cut to specific length at the panelmanufacturing site. Thus if a shorter length is needed for a particularportion of the wall run, the needed length can be cut e.g. from a20-foot section or from a continuous section. If a longer length pieceis needed, either a longer length panel can be fabricated as a unitaryproduct at the panel-manufacturing site, or 2 pieces can be joinedtogether using suitable straight-run connectors, or corner connectors,as suitable for the particular assembly to be made. The respectivebuilding panels can be cut to length, using e.g. a circular saw, a ringsaw, or a reciprocating saw, employing e.g. a masonry blade, andassembled on site.

Because the wall assembly is made primarily from fiberglass, resin, andfoam, the pounds per cubic foot density, and thus the unit weight perfoot of length is relatively small compared to a concrete wall ofcorresponding dimensions. For example, a building panel 20 feet inlength, 8 feet in height, and nominally 3 inches thick, weighs about 230pounds, including studs 23, and anchor brackets discussed elsewhereherein.

Similarly, a wall 9 feet high weighs about 10 pounds to about 15 poundsper lineal foot. Accordingly, no crane is needed on site for wallerection at or near ground level, or below ground level such as for afoundation wall. Rather, such wall panels can readily be moved by manuallabor only. Indeed, 2-4 workers can lift by hand, and emplace, a typicalwall section which is 20 feet long, 8 feet high, and 3-5 inchesthickness “T”. Rough openings for windows 27 and/or doors 29,illustrated in FIG. 1, can be cut on site using the above-noted masonryblade. Accessories, and other connections between elements of the walland between the wall and other building elements, can be mounted bydrilling and bolting conventional building construction elements to thebuilding panel, or by use of self-tapping fasteners driven into thebuilding panel, or by adhesive.

FIGS. 7-9 represent a second embodiment of wall structures, and walls,of the invention, which have a second structural expression of extendingthe reinforcing structure across the thickness of the wall panel. FIG. 7represents a top view of a portion of a foundation wall, including a 90degree corner in the foundation wall. FIG. 8 is an enlargedcross-section, in plan view, of a portion of the foundation wall shownin FIG. 7. FIG. 9 is a cross-section, in elevation view, of a portion ofthe foundation wall shown in FIGS. 7 and 8.

FIG. 7 shows that a substantial portion of the volume of the foundationwall is occupied by the series of blocks 32 of low-density insulatingfoam. As in the embodiments of FIGS. 1-6, inner 34 and outer 36 layersof fiberglass-reinforced resin form the generic inner and outer layersof the wall panels 14.

As best seen in FIG. 8, studs 23 are omitted, and at least part of thereinforcing function of studs 23 is provided by a continuous,reinforcing, weaving layer 50. Weaving layer 50 weaves back and forthfrom one of the inner 34 and outer 36 layers to the other of the innerand outer layers, between each of the foam blocks 32, namely at spacedcrossing locations, spaced along the length of the building panel. Suchcrossings are typically spaced from each other, along the length of thebuilding panel, by about 4 inches to about 24 inches, typically by about6 inches to about 12 inches. More typically, the foam blocks are about 8inches wide such that the crossings are spaced about 8 inches from eachother. As with the inner and outer layers, for conventional residentialsingle-family construction, the weaving layer, at the crossinglocations, has a nominal thickness of about 0.03 inch thick to about0.14 inch thick.

Thus, referring to FIG. 8, weaving layer 50 extends from left to rightalong the inner surface 42 of outer fiberglass layer 36, between layer36 and a foam block 32A to the edge of the width “W” of foam block 32A.Still referring to FIG. 8, at the right edge of foam block 32A, weavinglayer 50 turns a 90 degree angle and extends to the inner surface 52 ofinner fiberglass layer 34. At the inner surface 52 of inner fiberglasslayer 34, the weaving layer makes another 90 degree turn, and extends tothe right along inner surface 52 of the inner fiberglass layer along thefull width of foam block 32B, then turns and again goes back to theinner surface of outer fiberglass layer 36. Weaving layer 50 thusfollows a back and forth path between the inner 42, 52 surfaces of innerand outer layers 34, 36, along the entire length of the respective wallpanel 14. Layer 50 is in generally complete surface-to-surface contactwith the respective layers 34 and 36, and with the respective foamblocks 32, along the entirety, or substantially the entirety of its pathand along substantially all portions of the respective facing surfacesof layers 34 and 36, and foam blocks 32.

The respective layers 34, 36, 50, and foam blocks 32, are all integrallybonded to each other to make a unitary composite structural product.Thus, the weaving layer is attached to respective elements of both theinner and outer layers, whereby the thicknesses of the inner and outerlayers, as combined with the weaving layer, vary between relativelysubstantially thicker portions and relatively substantially thinnerportions. Typically, the relatively thicker portions of the combinedlayers 34, 50 and 36, 50 are at least 50 percent thicker than therelatively thinner portions of the layers 34 and 36. The resultantcomposite product functions much like an I-beam where layers 34 and 36,and combined elements of layer 50, serve as flange elements of theI-beam-like structure, and the crossing portions of weaving layer 50,function as web elements of such I-beam-like structures.

The foam blocks provide a thermally insulating function. In addition,foam blocks 32, along with the bonding of the respective elements toeach other, and the absence of substantial voids in the wall structure,serve to fix each layer 34, 36, and 50 in position along its intendedpath of traverse, relative to remaining elements of the structuralbuilding panel, thereby unifying layers 34, 36, 50 and blocks 32 into asingle structural product where the respective elements cooperativelyrespond together, in support of each other, sharing, with each other,respective portions of the load when outside forces are imposed on thestructural building panel.

In general, all the space between the inner surface 57 of the panel andthe outer surface 56 of the panel is occupied by one of layers 34, 36,and 50, or by the foam blocks, whereby little, if any, of the spacebetween layers 34 and 36 is not occupied by one of the above-recitedpanel materials. Typically, substantially all of the inner space isoccupied. By so generally filling the space between layers 34, 36, allof the panel members are fixed in their positions relative to eachother, and the panel is dimensionally quite stable under designedloading, whereby especially laterally-directed loads imposed on thepanel, from outside the building, whether subterranean ground loads orabove-grade e.g. wind loads, are efficiently transferred from outerlayer 36 to the other members of the panel, and respective portions oflayers 34, 36, and 50, and multiple ones of the foam blocks, share inthe support of any one load. The resulting panel is stiff, rigid, andsufficiently strong to support all loads, including severe weatherloads, to which the building is expected to be typically subjected undernormal use environments, including normal seasonal environmentalextremes in the given geographical location.

FIGS. 7, 8, 9, and 16 also show a plurality of resin-impregnated hollowfiberglass reinforcing channel studs 123. A respective hollow channelstud 123, as illustrated, is a unitary structure which has first andsecond flanges 126 interfacing with the outer surface of inner layer 34.Flanges 126 are bonded to inner layer 34 either through the resin whichforms part of layer 34, or through a separate adhesive or resin layerwhich bonds the flanges to layer 34. Upstanding legs 128 extend fromflanges 126 to an end panel 130. End panel 130 forms the surface of thechannel stud which extends to the greatest extent into the interior ofthe building, and away from the outer surface 56 of the building panel.In the panel assembly, a hollow space 133 is defined inside a respectivestud 123. Hollow space 133 is enclosed by the combination of end panel130, legs 128, and either inner layer 34 as in FIGS. 8 and 28 or a foamblock 32 as in FIGS. 26 and 29.

Flanges 126, legs 128, and end panel 130 generally form a unitarystructure. The structure of channel stud 123 can be relatively thin, forexample end panel 130 and legs 128 can be about 0.75 mm to about 3.8 mmthick. Typically, the end panel is displaced from the flanges by about 1inch to about 5.5 inches, optionally about 2 inches to about 3.5 inches.Even in the recited such thin cross-section, in light of the distancebetween the end panel and the flanges, stud 123 makes a meaningfulcontribution to the ability of the panel to resist lateral, e.g.bending, forces imposed by ground forces, or wind forces, from outsidethe building.

Additional contributions to lateral-resistance strength can be developedby making studs according to a more robust structural specification orby placing a rigidifying insert inside the cavities in the studs. Forexample, studs 123 can be fiber-reinforced pultruded rectangularcross-section studs about e.g. 0.07 inch (1.8 mm) to about 0.5 inch (13mm) wall thickness.

Studs 123 serve multiple functions. As a first function, studs 123 serveas mounting locations, for mounting surface materials such as sheetrock, paneling, or other interior sheet material 129, as illustrated inFIG. 26, to form the interior finished surface of the wall as occupiedliving space. Still referring to FIG. 26, the space 131 between thestuds provides channels for running e.g. additional insulation 135,and/or utilities 137 such as electricity, plumbing, and/or air ducting.Such utilities can also be run internally inside the hollow space 133defined between an end panel 130 of a stud 123, and layer 34. Anotherprimary function of the stud is that the stud enhances both the verticalcompressive strength and the horizontal point loading bending momentresistance strength of the wall. Thus, in the embodiments of FIG. 26,studs 123 and the crossing portions of weaving layer 50 can becollectively designed to provide the strength attributed tostructurally-reinforcing stud 23 of FIG. 6.

FIG. 16A shows a second embodiment of studs 123. In the embodiments ofFIG. 16A, the two outwardly-disposed flanges 126 are replaced with asingle bridging flange 126 which connects the legs 128, whereby a stud123 of FIG. 16A represents an elongated enclosed rectangular body,encompassing hollow space 133, and open at opposing ends of the stud.The studs 123 of FIG. 16A can be used generally any place the studs ofFIG. 16 can be used. For example, such studs can be joined to the panelassembly at the top of inner layer 34 as illustrated the FIGS. 8 and 28.For example, the studs of FIG. 16A can be joined to the foam blocks, andthe inner layer 34 applied over the studs as illustrated in FIGS. 26 and29.

FIG. 16B shows a third embodiment of studs 123. As in the embodiments ofFIGS. 16 and 16A, studs 123 of FIG. 16B are made by impregnating afiberglass matt with resin in a non-pultruded process, and curing theresin. In the embodiments of FIG. 16B, the two outwardly-disposedflanges 126 are replaced with a single bridging flange 126 as in theembodiments of FIGS. 16A, and the depths of legs 128 are extended,compared to the legs shown in FIGS. 16 and 16A. Namely, legs 128 in theembodiments of FIG. 16B are long enough that the stud can be mounted inthe panel assembly at or adjacent outer layer 36. Thus, the studs 123 ofFIG. 16B can be mounted in the panel assembly in a configuration whereinthe studs 123 replace studs 23 illustrated in FIG. 6. However, studs 123are typically hollow, whereby the hollow space 133 extends from theouter side of the building panel at layer 36 to end panel 130. FIG. 35illustrates hollow fiber-reinforced polymeric studs 123 of FIG. 16Bassembled into a building panel of the invention.

FIGS. 7-9, 20, and 20A illustrate a plate anchor brackets 24 and 24A. Abracket 24 or 24A is mounted to the interior surface of inner layer 34at the top of the wall panel, and is optionally also bonded to stud 123through a side panel 138. Line representations of brackets 24 and 24Aare illustrated in FIGS. 20 and 20A. Referring to FIG. 20, top panel 136of bracket 24 extends transversely from, and is joined to, the top ofbase panel 134. First and second side panels 138 extend transverselyfrom, and are joined to, both base panel 134 and top panel 136, thussupporting top panel 136 from base panel 134, and supporting base panel134 from top panel 136.

Base panel 134 of bracket 24 is positioned against inner layer 34 of thewall panel 14 and is mounted to inner layer 34 and optionally is mountedto stud 123 at side panel 138. Panels 134 and 138 can be mounted toinner layer 34 and stud 123 adhesively, or can be pressed into innerlayer 34 and/or stud 123 before the inner layer resin, or the studresin, is cured, whereby the curing of the resin in the inner layer orstud serves to bond panel 134 to inner layer 34 and/or stud 123. Toppanel 136 interfaces with and supports top plate 20, and typically isbolted to the top plate as illustrated in FIG. 9, whereby bracket 24serves to transfer loads between top plate 20 and the main portion ofthe wall panel, thereby making the top plate an integral part of thefoundation wall.

As suggested in FIG. 8, one of side panels 138 is used to attach bracket24 to stud 123, while base panel 134 is used to attach the bracket toinner layer 34. Accordingly, the second side panel has no attachmentfunction, and can thus be omitted in some embodiments. Bracket 24A ofFIG. 20A illustrates such embodiment where bracket 24A is the same asbracket 24 of FIG. 20, with the exception of providing only a singleside panel 138.

FIG. 9 illustrates, in side elevation view, the interface of top plateanchor bracket 24 with top plate 20. In the illustrated embodiment, thetop plate is a conventional wood board, and is secured to bracket 24 bya bolt 139 through top panel 136. FIG. 9 also illustrates a secondanchor bracket 24 used in supporting the interface between the wallpanel and bottom plate 16.

FIGS. 7 and 22 illustrate joining together of two wall panels 14A and14B using an “H” connector bracket 140. A line representation of “H”connector bracket 140, alone, is illustrated in FIG. 17. In “H”connector bracket 140, first and second parallel flanges 142, 144 areconnected, at perpendicular angles, to opposing edges of an intermediateweb 146. In some instances, a single flange 142 or 144 can be used oneither of the inner surfaces or the outer surfaces of the wall panelswhich are being joined to each other. The surfaces of the wall panels14A, 14B, and the “H” connector bracket, where the “H” connector bracketis in surface-to-surface relationship with wall panels 14A and 14B arebonded to each other. Such bonding can be achieved with known adhesives.In the alternative, the surfaces of the “H” connector bracket and/or thewall panels can be coated with uncured portions of the curable resin,which is subsequently cured after the wall panels are joined with the“H” connector bracket at the construction site. Such curing can be donewith heat guns or the like if and as heat is a necessary element of thecuring of the selected polymeric resin composition.

FIGS. 7 and 23 illustrate joining together of two wall panels 14A and14C using first and second corner brackets 148 and 150. Each cornerbracket has first and second panels 152 which meet at a 90 degree angleat a respective corner 154. A line representation of an angle bracket148, alone, is illustrated in FIG. 18. Since the only difference betweenbrackets 148 and 150 is the relative widths of the panels 152, onlybracket 148 is shown alone as at FIG. 18.

The interfacing surfaces 152 of corner brackets 148, 150 and wall panels14A and 14C, at panels 152 of the brackets, are bonded to each other.Such bonding can be achieved with known adhesives. Brackets 148, 150 canbe held in place with e.g. self-tapping mechanical fasteners whilebonding is being achieved. In the alternative, the surfaces of the anglebrackets and/or the panels can be coated with uncured portions ofcurable resin, which is subsequently cured after the panels are joinedwith the angle brackets at the construction site. Such curing can bedone with e.g. heat guns or the like if and as heat is a necessaryelement of such curing.

FIG. 24 illustrates a bracket 160 which can be used as a single-bracketcorner construct. Bracket 160 has inner panels 152A, outer panels 152Bas in brackets 148 and 150, and also has a connecting panel 162 whichconnects the inner panels to the outer panels at corner 154 where theinner panels 152A meet.

FIG. 19 illustrates a variable-angle bracket 170 which has rigid panels152, and a flexible hinge area 172 which can be flexed to any includedangle of from about 0 degrees to about 180 degrees. Bracket 170 is usedto join together wall panels at joints where the panels 14 are neitherperpendicular to each other nor aligned with each other. Once rigidpanels 152 have been bonded to surfaces of the building panels 14 whichare being joined, and the building panels have been set at the desiredincluded angle to each other, the flexible hinge area can be made rigidby applying, to the hinge area 172, a coating of the hardening curable2-part resin such as is used to make building panels 14 and bracketpanels 152. The same bonding, and making rigid, can also be done usingwell known and conventional, curing, hardening construction adhesives.

FIG. 9 illustrates, in edge view, the addition of a fiberglass/resinsupport bracket 48 (FIG. 15) against the outer surface 56 of the wall.FIG. 4 illustrates, from a side elevation view of the outer surface ofthe wall, the extension of support bracket 48 as a brick ledge, alongthe full length of the main-run wall section. Bracket 48 transfers theweight of overlying bricks 175 to the underlying wall 10.

Still referring to FIG. 9, support bracket 48 extends outwardly from theouter surface 56 of the wall panel a sufficient distance, such as about4 inches to about 5 inches, to support conventional brick or stonefacing on the outside of the building. As indicated in FIG. 9, aftercompletion of the construction work, earth or other backfill 174typically fills up the excavated cavity around the foundation wall, to alevel at or above brick support panel 176, thus concealing bracket 48.

Support bracket 48 can be installed facing inwardly at the top of ane.g. garage wall, thereby providing vertical edge support to asubsequently-poured concrete garage floor. Similarly, bracket 48 can beinstalled facing outwardly at the top of an e.g. garage or other wall,thereby providing vertical edge support to subsequently-installed brickor stone. First and second complementary brackets 48 can be mounted, oneon top of the other, with brick support panel 176 of the first bracket48 facing away from the building and the brick support panel 176 of thesecond bracket facing into the building. Such use of 2 brackets providesfor wall support of both an adjoining edge of the garage floor and brickor stone exterior fascia, both of which are adjacent the foundationwall.

A line representation of support bracket 48 is illustrated in FIG. 15.In the upright use orientation illustrated in FIGS. 3, 9, and 15, a basepanel 178 of bracket 48 is oriented vertically along the outer surface56 of building panel 14, and can optionally be bonded to panel 14. Thebrick support panel 176 extends outwardly from the base panel, above thebottom edge of the base panel. A bracing panel 180 extends upwardly fromthe bottom edge of the base panel to the outer edge of the brick supportpanel, transferring upwardly-directed structural support from the basepanel to the outer edge of the brick support panel. An upper panel 182extends horizontally from the top edge of the base panel and terminatesat a downwardly-directed keeper panel 184. Upper panel 182 and keeperpanel 184 collectively mount/hang the support bracket 48 from the topsurface of the wall panel 14.

FIG. 21 illustrates a second embodiment of the support bracket, namely atwo-sided support bracket which is designated as 188. Bracket 188 isdesigned and configured to support both (i) an edge of a garage floorwhich generally abuts the inwardly-facing surface of the foundation walland (ii) a brick or stone fascia which generally faces theoutwardly-facing surface of an upper portion of the foundation wall, aswell as an upstanding e.g. above-grade wall which overlies thefoundation wall. The edge of the garage floor overlies a first supportpanel of the support bracket and thus loads the support bracket on theinward side of the foundation wall. The brick or stone fascia overlies asecond support panel of the support bracket and thus loads the supportbracket on the outward side of the foundation wall. The loads imposed onthe support panels are passed from the support bracket through thefoundation wall to the footer, and thence to the underlying soil orother natural base which supports the respective wall.

As with support bracket 48, the two-sided support bracket 188 isinstalled at the top of the wall panel such that upper panel 182 bearsupon the top surface of the wall panel. Base panel 178A extendsdownwardly from upper panel 182. Support panel 176A extends outwardlyfrom base panel 178A, and is supported by bracing panel 180A. A secondbase panel 178B extends downwardly from upper panel 182, typically butnot necessarily, a similar distance as base panel 178A so as toterminate at a lower edge having generally the same installed elevationas base panel 178A. Support panel 176B extends outwardly from base panel178B, and is supported by bracing panel 180B.

A single support bracket 188 can thus be used in place of theabove-recited first and second support brackets 48 where a concretegrade-level garage floor abuts the top of the foundation wall and abrick or stone fascia is mounted to the other side of the foundationwall.

Similar to the operation of bracket 48, support panels 176A, 176Btransfer the weight of the overlying e.g. loads of the brick or stonefascia, and the edge of the garage floor, to the wall, thence throughthe footer, and to the underlying natural base of e.g. soil or rockwhich supports the building. As illustrated in FIGS. 9A, 9B, brackets48, and correspondingly brackets 188, can be used to support the bottomsof the floor joists or other floor support members below the top of thewall such that the top of the floor 40 is at an elevation no higher thana height which is defined above the foundation wall a distance less thanone time the height of the floor structure. In the embodiment shown, thetop of the floor structure is at approximately the same elevation as thetop of the foundation wall. The ends of the floor support members aredisposed inwardly of the outer surface of the foundation wall andinwardly of inwardly-facing surface 25 of the foundation wall. Thesub-floor and finished flooring, which overlie the floor supportmembers, can extend beyond the floor support members as desired. Suchlowering of the height of e.g. a ground floor can facilitateconstruction for handicapped entry to the building.

Similarly, brackets 48 can be configured to support the bottoms of thefloor joists at any desired elevation below the top of the wall suchthat the top of the floor is at any corresponding elevation, relative tothe top of the foundation wall, up to a maximum height which is aboutthe same as the elevation shown in FIG. 9. Such configuring of brackets48, 188 can thus be used to support floor joists corresponding tobuilding floors which are above grade as well as building floors whichare below grade. For example, where 2 floors of a building are belowgrade, brackets 48 can be so used to support floor joists on suchbelow-grade floors, as well as one or more above-grade floors.

While brackets 48 and 188 have been described herein as being used withbuilding panels of the invention, brackets 48 and 188, when properlysized and configured, can be used with conventional e.g. concrete wallssuch as frost walls and foundation walls so long as upper panel 182 issized to fit on such conventional wall.

Returning again to FIG. 9, bottom plate 16, as illustrated, can be arather thin, e.g. about 0.18 inch to about 0.50 inch thick, stiff andrigid resinous pultrusion which has sufficient stiffness and rigidity tospread the vertical load for which the panel is designed, out oversubstantially the full downwardly-facing surface area of the bottomplate, thus transferring the vertical load to the underlying e.g.aggregate stone fabricated base.

In some embodiments, an e.g. conventional concrete footer 55 isinterposed between the natural underlying soil, or clean aggregate stonebase, and the bottom plate 16. In such instance, any of a wide varietyof conventionally available pliable, crushable, and curable liquid,paste, or the like deformable gasketing or other bridging material 51 ofchangeable form, or gasketing or other bridging material of defined butcrushable form, such as sheet material, is laid down on the footerbefore the wall panel is placed on the footer. Bridging material 51 isillustrated as a somewhat irregular thick dark line between concretefooter 55 and bottom plate 16 in FIG. 3. The wall panel is installedover the intervening gasketing or other deformable material before thedeformable material has cured, whereby the small interstices, spaces,between the footer and the wall panel are filled in by the deformablematerial.

When the deformable material cures, the deformable material becomes aload-bearing, bridging material, whereby the bridging material transferscorresponding portions of the overlying load across thepotentially-existing spaces, which have been filled with the bridgingmaterial, thus to provide a continuous load sharing interface betweenthe wall panel and the footer along the full length of the wall panel.Such bridging material can be any material sufficiently deformable totake on the contours of both the lower surface of plate 16 and the uppersurface of the footer, and which is curable to create theafore-mentioned structural bridging configuration.

Referring again to FIG. 9, concrete slab floor 38 is shown overlyingthat portion of bottom plate 16 which extends inwardly into the buildingfrom the inner surface 57 of wall panel 14, and inwardly from thechannel studs 123. Slab floor 38 abuts the inner surfaces of wall panel14 and channel studs 123, thus stabilizing the bottom end of the wallpanel against inwardly-directed forces which reach the lower end of thewall panel.

While described using differing nomenclature, namely wall surface andinner surface, inner surface 57 and wall surface 25 both represent thesame face of wall panel 14 when considered away from studs 23 and 123.Contrary to surface 25, inner surface 57 also includes the respectivesurface of the wall panel at studs 23, 123.

Inwardly-directed forces which reach the upper end of the wall panel areopposed by conventional attachments between the overlying main floor 40and top plate 20. Inwardly-directed forces which are imposed on wallpanel 14 between the top of the wall panel and the bottom of the wallpanel are transferred to the top and bottom of the wall panel, thence tothe concrete floor and the overlying main floor or floor system, throughthe stiffness and rigidity of the wall panel as collectively defined bythe interactions of the structure defined by layers 34, 36, 50, foamblocks 32, and studs 23, 123, if used. Other reinforcing structure canbe included, added to the wall, as desired in order to achieve thedesired level of lateral strength and rigidity in the wall structure.

In residential construction, a typical maximum vertical load experiencedby an underlying e.g. foundation wall is about 3000 pounds per linealfoot to about 5000 pounds per lineal foot. The vertical crushing loadcan be applied to the full width of the top of the wall anywhere alongthe length of the wall.

Typical maximum horizontal point load bending moment on such wall isabout 1000 pounds per square foot to about 1500 pounds per square foot.The horizontal loading is measured at 39 percent of the height up fromthe bottom of the otherwise horizontally-unsupported wall.

Referring to FIG. 8, a typical wall panel of the invention, for use inunderground applications such as foundation walls, has a nominalthickness “T” of about 3 inches. Studs 123 project about 3.5 inches frominner surface 25 of the wall panel. Inner layer 34, outer layer 36, andweaving layer 50 are all fiberglass reinforced plastic layers about 0.07inch thick. Studs 123 have walls about 0.07 inch thick. Foam blocks 32have densities of about 2.0 pcf to about 5 pcf. Such typical wall panelhas a vertical crush resistance capacity of about 15000 pounds perlineal foot, and a horizontal point loading bending moment resistance ofat least about 2000 pounds per square foot.

Depending on the safety factors desirably built into the buildingpanels, the vertical crush resistance can be as little as about 4000pounds per lineal foot, optionally at least about 6000 pounds per linealfoot, typically at least about 8000 pounds per lineal foot. At least10,000 pounds per lineal foot can be specified, as can at least 12,000pounds per lineal foot.

The bending resistance of the wall panel at the locus of maximumhorizontal underground loading is typically at least about 1500 poundsper square foot, and up to about 3000 pounds per square foot. Both thevertical crush resistance and the horizontal point loading bendingmoment resistance can be designed for greater or lesser magnitudes byspecifying, for example and without limitation, density of includedfoam; thickness of layers 34, 36, 50; wall thickness, spacing, and/ordepth “T1” of studs 23, 123, or thickness “T” of the panel, or thickness“T” in combination with depth “T1” the structure.

Above-ground side loads, such as wind loads, are less than theabove-recited 1500 pounds per square foot. Accordingly, the bendingresistance capabilities of building panels intended for above-groundapplications can be less than the above-recited 1500 pounds per squarefoot.

Panels expected to be used in below-grade applications are designed tosatisfy the load requirements experienced in below-grade applications,while panels expected to be used in above-grade applications aredesigned to satisfy the load requirements experienced in above-gradeapplications. Such design process includes considering weather and/orground movement history of the use location, as well as otherenvironmental factors. Thus, building panels of the invention include awide range of panel structures and properties, so as to provideengineered solutions which can be designed to fit the stressenvironments expected to be imposed on the specific building panelswhich are to be used in specific uses. One can, of course, also makebuilding panels of generic design which are designed to tolerate a widerange of expected loadings. For example, a first design specificationcan be made to satisfy most below-grade uses while a second designspecification can be made to satisfy most above-grade uses.

Returning to FIG. 1, as suggested above, conventional steel I-beams canbe used in combination with wall panels 14 of the invention. Asillustrated in FIG. 1, such I-beams are supported from the underlyingsoil at conventional spacings by posts 28 which transmit loads from theI-beam to the underlying soil, through a load-spreading pad 30. Inconventional structures, the load is transmitted by a conventional steelpost, to an underlying footer pad of concrete which is poured on theunderlying soil.

In the invention, in place of a concrete footer, multiple layers ofreinforced polymer composite, such as is used in wall panel 14, are usedin fabricating a support pad 30. A typical such support pad 30 isillustrated in FIG. 10, underlying a support post and supporting astructural floor-support beam 26.

A cross-section of a representative pad 30, on an underlying supportbase SB is illustrated in FIG. 10A. As illustrated in FIG. 10A, pad 30has an upwardly-facing top 30T and a downwardly-facing bottom 30B. Thesurface area of the bottom of the pad is selected to be large enough tospread the overlying load over enough of the natural soil and/or rockunderlying support base that the underlying support base can support theoverlying load over a generally indefinite period of time withoutdeleterious deformation or flow or other movement of the underlyingsupport base. The pad is constructed of a plurality ofgenerally-extending ones of the fiberglass-reinforced polymer compositelayers 31. The layers are, in general, positioned such that at least asubstantial portion of a relatively overlying layer overlies asubstantial portion of a relatively underlying layer, optionallyincluding geometrically designed intercostals for strength. Typically,the layers are stacked one on top of the other, optionally connected toeach other at the edges 33, as by folding one layer into anext-adjoining upper or lower layer, such that the respective stackingof the layers, layer on layer, results in facing, generally horizontallydisposed, portions of the respective layers supporting each other, andacting collectively, thus to provide pads having sufficient bendingresistance to bear downwardly-directed loads when the pads are in use.

Such layering can be created by folding and stacking a resin-wettedfiberglass layer in a mold, closing the mold and evacuating the air,thus to consolidate the pad, then curing the resin, resulting in thehardened fiber-reinforced polymeric pad. In the alternative, thefiberglass layering can be placed in the mold in dry condition, and theresin can be added while the mold is being evacuated.

Pad 30 is illustrated as having a generally square or round projectedarea, and as being used for spot support such as in support of a post28. Pad 30 can have an expanded projected area of any desired projectedconfiguration such as to underlie and support multiple posts in a singlearea. Further, pad 30 can have an elongate configuration whereby pad 30can be used as an elongate footer under, and supporting any number offoundation panels 14 when such panels are used in a fabricatedfoundation wall.

Thus, a typical support pad can have a projected area of about 1 squarefoot to about 10 square feet when designed to support a point load suchas a single post. A pad which is designed to support an e.g. elongateload such as a wall having a length of e.g. 10 feet, 20 feet, 40 feet,or more has an elongate dimension corresponding in magnitude to thelength of the wall.

The thickness of the pad is designed to support the magnitude of theanticipated overlying load. Thus, as with the building panels, for eachbuilding application, the pad represents an engineered solution based onthe anticipated load and load distribution. Magnitude of the load assupported by pad 30 generally corresponds to the load distributionconventionally contemplated for typical single-family residentialconstruction. Thus, the load distribution recited herein for foundationwalls can apply such that an elongate pad can support at least 5000pounds per lineal foot and a round or square pad can support loads of atleast about 2000 to about 5000 pounds per square foot, more typically atleast 3000-5000 pounds per square foot. Higher loadings can be supportedby suitably engineered such pads.

The thickness of a pad, between top 30T and bottom 30B depends in parton the load magnitude and load distribution, and in part on the specificresin as well as the specific structure of the reinforcing fibers andfiber layers, as well as on the nature of the construct of the pad. Forlight-weight construction, where the pad carries a relatively lighterload, the thickness of the pad can be as little as 1 inch thick. Wherethe pad bears heavier loads, the pad is thicker, and has the same orderof magnitude of thickness that would have been used if the material weresteel-reinforced concrete. Thus, pad thickness typically ranges fromabout 3 inches thick to about 16 inches thick, optionally about 6 inchesthick to about 16 inches thick, optionally about 8 inches thick to about16 inches thick, with all thicknesses between 1 inch and 16 inches beingcontemplated. Thicknesses less than 3 inches and greater than 16 inchesare contemplated where the anticipated vertical load and loaddistribution, along with the material properties, indicate suchthicknesses.

In general, the dimension of thickness is less than either the length orwidth dimension. As illustrated in e.g. FIG. 1, typically the magnitudeof the thickness dimensions is no more than half as great as themagnitude of the lesser of the length dimension or the width dimension.

In any event, the structure shown in FIG. 10A is not limiting as to thelayer structuring. For example, the layers of fiberglass can beconfigured as an elongate roll, where relatively outer layers arewrapped about one or more relatively inner or core layers.

In the alternative, as illustrated in FIG. 10B, pad 30 can be apultruded fiberglass-reinforced polymeric structure such as a solidpultruded plate or a rectangular tube positioned such that a cavity 37extends generally horizontally through the structure. Such rectangulartube has a generally horizontal top or inner web 34, a generallyhorizontal bottom or outer web 36, and one or more generally upstandingconnecting webs 35 which support the top web from the bottom web. In theembodiment illustrated in FIG. 10B, cavity 37 is hollow. In otherembodiments, a honeycomb or other web structure extends the length ofthe cavity 37, thus providing bridging structure between top web 34 andbottom web 36, which can provide structural support supporting the topweb from the bottom web and thereby take on some of the support functionof connecting web or webs 35.

The post 28 is generically represented in FIG. 1. While post 28 can besteel, and pad 30 can be concrete where wall panels of the invention areused, the invention contemplates that post 28 can be a hollowfiberglass-reinforced polymer composite structure. Curing resin as inthe pad and building panels can be used to mount and bond post 28 to thepad, with conventional shimming as desired.

Such resin-fiber composite post 28 has a generally enclosing structuralsidewall. The post sidewall is made of fiberglass-reinforced polymercomposite or other fiber reinforced resinous structure. The thicknessand rigidity of the post sidewall is designed as known in the art tocarry a specified load, thereby to support the weight of an overlyingportion of typically an above-grade structure, though below gradestructures can be supported as well. The enclosing post sidewall definesan interior chamber disposed inwardly of the enclosing sidewall. Theinterior chamber is typically empty, but can contain structural ornon-structural material as desired.

Where the fiberglass post 28 is used, a fiberglass-reinforced polymercomposite cap 58 is typically mounted over the top of the post. Cap 58has a top wall 60, and one or more downwardly-depending structuralskirts 62. Top wall 60 of the cap is sufficiently thick and rigid toreceive the load from the overlying beam and transmit the load generallyuniformly about the perimeter of the upstanding outer walls of the post,including where the outer walls may be disposed laterally outwardly fromthe edges of the beam. The structural skirt or skirts are configuredsuch that, when the cap is mounted on the post, with the top wall of thecap bearing down on the top of the post, the inner surface of thestructural skirt or skirts is/are in generally surface-to-surfacecontact with, or close proximity with, the outer surface of the post,such that the skirt structure receives and absorbs typically encounteredlateral forces and transfers such lateral forces to the sidewall of thepost, thereby preventing the top of the cap from moving laterallyrelative to the top of the post.

The cap distributes the lateral loads to the post side walls withlimited bending of the top wall of the cap, so as to utilizesubstantially the full load-bearing capacity of the post sidewalls, fromat or near the upper edge of the post, along the full height of the postto the underlying pad 30. The cap skirts thus capture lateral forces andtransfer such lateral forces to the post.

An alternative to cap 58 is to use a conventional adjustable screw 59 onthe top of post 28. Such screw 59 can be used in place of cap 58, or incombination with cap 58, e.g. between cap 58 and overlying beam 26.Where both cap 58 and screw 59 are used, a suitable screw/cap interfaceis configured in the screw and/or cap to ensure suitable cooperation ofthe cap and screw with respect to each other.

FIG. 11 illustrates a square fiberglass-reinforced polymer composite pad30 of the invention, a square fiberglass-reinforced polymer compositepost 28 of the invention, and a square fiberglass-reinforced polymercomposite cap 58 of the invention. FIG. 12 illustrates a pad/post/capcombination similar to that of FIG. 11 but where the pad is tapered fromthe top of a base of the pad upwardly to where the pad meets the post.FIG. 13 illustrates a pad/post/cap combination similar to that of FIG.11 but where the post, the pad, and the cap are circular. FIG. 14illustrates a pad/post/cap combination similar to that of FIG. 13 butwhere the pad is tapered from the top of a base of the pad upwardly towhere the pad meets the post.

While the pad/post/cap combinations shown in FIGS. 11-14 can be used onthe interior of the building such as in a basement post arrangement assuggested in FIG. 1, a primary purpose of the invention, of avoiding theneed to bring a ready-mix concrete truck to the construction site, isadvanced by using pad/post/cap combinations such as those illustrated inFIGS. 11-14 in applications outside the foundation of the building, suchas to support a deck, a porch, a patio, a light post, or otherappurtenance. In such application, the pad and post are set in theground below the frost line. The post is then cut off typically, but notnecessarily, below grade. Conventional structure such as a 4×4 treatedwood post is then mounted to the top of cap 58, and the cap issubsequently mounted, e.g. adhesively mounted, to the top of the post.With the e.g. 4×4 post thus extending upwardly, with the cap permanentlye.g. adhesively mounted to the post, the hole is filled to grade suchthat only the conventionally-used wood post remains visible. Thus,typical outside appurtenances to the building can be completed, againwithout any need to bring ready-mix concrete, or concrete block, to theconstruction site. This can provide a significant time and costadvantage when only a small amount of concrete would have otherwise beenneeded, as the trucking cost is fixed, even for a small quantity ofready-mix concrete.

In other embodiments, the fiberglass post 28 can extend above grade, andcan support any of a wide variety of suitable overlying structures.

As indicated above, one of the objectives of the invention is to usewall panels and accessory structure in places, and for structuralpurposes, where concrete would conventionally be used. Use of concretein foundation walls is common, and the products of the invention arereadily adapted to be used in foundation structures.

However, especially in more tropical climates, above-ground outsidewalls are, in some instances, required to be built with concrete for thepurpose of, among other advantages, inhibiting mold growth. Where highwind conditions, such as hurricanes or tornadoes, are common,above-grade outside walls are, in some instances, required to be builtwith concrete in order to achieve additional lateral strength which canwithstand such wind forces.

In such situations, such as in areas frequented by hurricanes ortornadoes, above-ground wall structures of the invention can be used inplace of concrete, while achieving the lateral load-bearing propertiesof concrete and avoiding the e.g. water penetration, and other,limitations inherent in concrete. Accordingly, the wall structures ofthe invention are contemplated to be useful in above-ground applicationsas well as below-ground/foundation wall applications.

The Fiber

The reinforcing fiber materials used in products of the invention can beselected from a wide variety of conventionally available fiber products.Glass fiber has been illustrated in the general description of theinvention, and is believed to be the most cost effective material. Otherfibers which are contemplated as being acceptable include, withoutlimitation, carbon fibers, Kevlar fibers, and metal fibers such ascopper and aluminum. Other fibers can be selected to the extent theirreinforcing and other properties satisfy the structural demands of thebuilding panel applications contemplated in the invention, and so longas the fibers are not pre-maturely degraded in the use environmentcontemplated for the respective wall panels.

To that end, use of cellulosic fibers is limited to those compositionswhere the cellulosic fiber can be suitably protected from thedeleterious affect of moisture reaching the fiber and degrading thefiber. Thus, use of cellulosic fiber without moisture protection is notcontemplated as part of the invention, except in amounts of less than 10percent by weight of the overall composition of a given structuralelement, e.g. panel, bracket, or the like. However, where the fiber isimpregnated with a suitable quantity of resin, the resin protects thecellulosic fiber from attack by moisture, and so such compositecompositions can be used.

The lengths, widths, and cross-sectional shapes of the fibers areselectable according to the structural demands of the structures inwhich the building panels or other structures are to be used.

Woven-fiber base sheets, such as woven fiberglass cloth, arecontemplated as being efficiently processed into layers for use inbuilding panels of the invention. However, those skilled in the art willrecognize that a wide variety of processes, and corresponding ways ofhandling and processing the fibers, as well as the resin, are availablefor making the building panels of the invention. The selection of fiberstructures can be specified to accommodate all such processes, wherebyall fibers which can be employed in all such processes, for examplechop, matt, or woven fibrous material, to achieve the desiredstructural, insulation, and other properties typically desirable in afoundation wall, or an above-grade wall, can be used in building panelsand other elements of the invention.

Reinforcing fibers are generally known as dry fibers or pre-impregnatedfibers for purposes of the process of fabricating reinforced resinousproducts with such fibers. The fibers contemplated for use herein aretypically dry fibers, though some wet fiber processes are contemplatedas being useful in making products of the invention.

The Polymer

The polymer which is used to impregnate and/or carry the fiber can beselected from a wide variety of conventionally available multiple-partreaction-curing resin compositions. Typical resin is a 2-part liquidwhere two liquid parts are mixed together before the resin is applied tothe fiber substrate. Third additional components can be used in thereaction mixture as desired in order to achieve the desired level ofreaction curing of the resin. The resin mixture should be sufficientlyliquidous to be readily applied and spread about a fiber basesheet/substrate thereby to fill in all of the voids in the substrate.Examples of useful 2-part reaction curing resins include, withoutlimitation, epoxy resins, vinyl ester resins, polyester resins,polyurethane resins, and phenolic resins. Those skilled in the art knowthat each of the above noted resins represents a large family ofreactable materials which can be utilized to make the resultantreaction-cured resin, and are capable of selecting reaction resincombinations for the uses contemplated in the invention. In addition,more than two such resins can be mixed to obtain a desired set ofproperties in the reaction product or process.

For any set of reaction materials which are used to make the resinsillustrated here, any conventional additive package can be included suchas, for example and without limitation, catalysts, anti-oxidants, UVinhibitors, fire retardants, and fluidity-control agents, to enhance theprocess of applying the resin and/or curing the resin, and/or to enhancethe properties of the finished product, e.g. weather resistance, fireresistance, hardness, and the like.

Each set of two or more materials which can be mixed and reacted to makethe resultant resin product has its own reaction parameters, includingdesired reaction temperature, catalysts, time required for the curingreaction to take place, and the like. Further, each set of such two ormore materials develops its own set of resultant physical and chemicalproperties as a result of the curing process. Especially the physicalproperties are influenced by the affect of the included fibers, suchthat more than two such reactants may be useful in achieving, in thereacted polymer, a desired set of physical properties.

The Polymer/Fiber Composite

In general, dry fiber substrate, woven cloth, or fiber matt, is used asthe fiber base for all structural layers such as layers 34, 36, 50; aswell as for all other structural elements of the invention such asposts, 28, pads 30, caps 58, channel studs 123, and brackets 48, 140,148, 150, 160, 170, and 188. Since the objective is to fill insubstantially all voids in the fiber substrate with resin, enough resinis added to the fiber substrate to fill all such voids, whereby thereshould be no air inclusions, or so few air inclusions as to have nomaterial affect on the physical or chemical stability, or the physicalproperties, of a building panel or other structure built with suchresin-impregnated fiber-based layer. Overall, the glass/resin ratio isas high as can be achieved, and not leaving any significant, deleteriousvoids in the resultant layer once the resin is cured.

In the alternative, layers 34, 36, 50 can be fabricated usingpre-impregnated layers of fiberglass, namely fiberglass substrates whichhave been pre-impregnated with resin before being fabricated into astructural element pre-form, and which can be cured by e.g. applicationof heat as in a curing oven.

Given the requirement to minimize voids, and using conventionallayer-development techniques, the resultant structural layer product,e.g. layer 34, 36, or 50, or other product, is about 30 percent byweight to about 65 percent by weight fiberglass, and correspondinglyabout 70 percent by weight to about 35 percent by weight resin.Optionally, the resultant layer is about 40 percent by weight to about60 percent by weight fiber and about 60 percent by weight to about 40percent by weight resin. A typical resultant layer is about 45 percentby weight to about 55 percent by weight fiberglass and about 55 percentby weight to about 45 percent by weight resin, optionally about 50percent by weight fiberglass and about 50 percent by weight resin.

According to well-known technology, the number of layers of glass, incombination with the weight of the glass per layer, in generaldetermines the thickness of the resultant layer after theresin-impregnated layer is cured. For example, multiple layers of a12-17 ounce per square yard layer of woven fiberglass cloth can beimpregnated to fill all voids, and to thereby achieve a resultant curedstructure which is typically between about 1 millimeter thick and about2.5 millimeters thick (between about 0.04 inch thick and about 0.10 inchthick). The greater the number of layers of fiberglass which areimpregnated, typically the greater the thickness of the resultingimpregnated and cured composite reinforced layer.

The top and bottom plates, as well as layers 34, 36, and 50 can be madeof such polymer/fiber composite. The bottom plate can be any materialwhich can bear the load imposed on the overlying wall panel. A typicalbottom plate is an e.g. about 0.18 inch thick to about 0.50 inch thickfiber-reinforced pultrusion, which is sufficiently stiff and rigid tospread the overlying load to the underlying soil substrate generallyuniformly along the length of the panel through an e.g. leveled cleanaggregate stone base. The stone may be a crushed stone or an uncrushedaggregate stone.

Top plate 20 can be made of, without limitation, fiberglass-reinforced,or other fiber-reinforced, resinous materials, or other materials suchas wood, in the shape conventionally used for a top plate. It iscontemplated that a conventional wood-based top plate serves the purposeadequately, and provides for attachment of overlying wood elements suchas wood framing, using conventional fasteners and conventional fasteningmethods.

The Foam

The purpose of the foam, such as in foam blocks 32, is generallytwo-fold. First, the foam contributes to the structural integrity of thebuilding panel structure by being sufficiently rigid, namely a rigidfoam, that the foam contributes significantly to fixing the structurallayers 34, 36, and 50 in their designated positions under normal loadingof the panel, whether vertical gravitational loading, or lateral loadingsuch as lateral ground loads in below-grade applications, and lateralwind and/or water loads in above-grade applications. Thus, the foammakes a substantial contribution to the dimensional stability of panel14.

Second, the foam provides substantial thermal insulation to theresulting building panel construct.

In achieving a desirable level of thermal insulation while retaining thefoam as a rigid closed-cell material, the foam has a density of about 1pound per cubic foot (pcf) to about 12 pcf, optionally about 2 pcf toabout 8 pcf, optionally about 2.0 pcf to about 5 pcf. Lighter weightfoams generally do not provide sufficient rigidity to perform the roleof the foam in fixing the structural layers in their designatedlocations and such lighter-weight foams may be open-cell foams. Whileheavier weight foams can be used, and typically provide more structuralstrength, such heavier weight foams provide less than the desired levelof thermal insulation properties, and are more costly. In general, thefoams used in the invention are closed-cell foams.

Foam blocks 32 can be made from a wide variety of compositionsincluding, without limitation, extruded polystyrene foam, expanded beadpolystyrene foam, rigid urethane foam, or polyisocyanurate foam. Thefoam is moisture resistant, preferably moisture proof, and is chemicallyand physically compatible with the compositions and structures of layers34, 36, and 50.

Regarding fixing the respective structural layers in their designatedpositions, the foam fills all, or substantially all, of the spacesbetween the respective surfaces of the structural layers 34, 36, and 50,and is in surface-to-surface contact with the respective layers as suchlayers define the cavities in which the foam is received. In addition,the foam is adhered to the respective structural layers so as to absorbsheer forces between the foam and the respective structural layers.

The foam blocks 32 can be brought into surface-to-surface relationshipwith one or more of the structural layers 34, 36, 50 after the resin hasbeen applied to the respective fiber substrate which is used to form thelayers and before the resin has cured, whereby respective one or moresurfaces of the foam blocks, which are in surface-to-surface contactwith the respective resin-coated fiber substrate, become wetted with theuncured resin. With the foam in contact with the to-be-curedfiber-reinforced layer, and wetted by the fiber-reinforced layer, thecuring of the resin bonds the foam blocks to the structural layer 34,36, 50 as applies, whereby no separate adhesive is necessarily requiredto bond the foam blocks to the structural layers.

Throughout this teaching, reference has been made to affixing variouselements of the building panels to each other. In some cases, mechanicalaccessories such as bolts have been mentioned, such as for attaching thetop plate to bracket 24. In instances where two elements are affixed toeach other, and where both elements contain resin components, especiallyreaction-cured components, the curing of the resin in any two suchstructural elements being formed or joined can be used to affix theelements to each other such that no further adhesive need be used. Onthe other hand, where components are assembled to each other at theconstruction site, at least in some instances, use of e.g. conventionaladhesives and sealants which are known for utility in constructionprojects, is contemplated.

One example of use of construction adhesive in assembling the foundationwall is affixing the bottom plate to a wall panel 14. Wall panels 14 canbe transported to the construction site without top plate or bottomplate, and wherein top plate materials and bottom plate materials can betransported to the construction site separately, although potentially onthe same vehicle. Bottom plates and top plates are then affixed to thewall panels at the construction site, as desired. The bottom plate istypically affixed to the bottom of the wall panel with a constructionadhesive, with or without the assistance of brackets 24. The top platecan be affixed to the top of the wall panel using brackets 24 and bolts139, and/or other support as needed, and optionally in addition,adhesive between the top plate and the top of the wall panel.

Brackets 48, 140, 148, 150, 160, and 170 can be adhesively mounted tothe building panels. In the alternative, the surfaces of the respectiveparts, including the respective areas of the building panels, can becoated with a supply of the curing resin before the parts are assembled,and the parts can then be held together for a sufficient time, undersatisfactory conditions, which result in the curing of the resin,whereby the curing of the resin develops the necessary level ofaffixation between the respective parts of the wall.

In the same way, either adhesively or by use of curable resin materials,channel studs 123, support brackets 24, 48, and floor-and-garage apronbrackets 188 can be mounted to a wall panel after the wall panel reachesthe construction site.

It will be understood that any affixation of bracket 24 to the innersurface of the wall panel must be generally fully developed as to itsrequired operating strength before the top plate or bottom plate, asapplies, can be affixed to the wall panel and apply its rated load tobracket 24.

EXAMPLE

In general, wall structures of the invention can be engineered tosupport any level of compressive load which is contemplated to beapplied to the building. For example, and without limitation, usingconventional woven fiberglass substrate, a demonstrative foundationbuilding panel, such as the panel illustrated in cross-section in FIG.8, can be built generally as follows, and having a designed compressiveload bearing capacity of about 15000 pounds per lineal foot of the wallpanel.

Woven fiberglass is used for the base, e.g. substrate of structurallayers 34, 36, and 50, as well as for the base substrate for channelstuds 123. The fiberglass substrate can be triax woven fiber substratehaving basis weight of about 22 ounces per square yard. Anotherexemplary fiberglass substrate is a bi/uniax woven fiber substratehaving basis weight of about 12 ounces per square yard to about 22ounces per square yard. Yet another example is a woven roving havingbasis weight of about 17 ounces per square yard.

The selected fiberglass substrate, for example a 22 ounce wovensubstrate, is laid out on a horizontally-disposed release material suchas a layer of MYLAR® oriented nylon. Other materials may be substitutedfor the release sheet and become part of the finished wall panel whileachieving separation from the processing line as well as to achieve adesired exterior finish on the wall panel. The fiberglass substrate isbrushed or otherwise impregnated with a curable 2-part epoxy resin insufficient quantity and in such process as to fill in substantially allof the voids in the woven fiber substrate, thus to create a firstpre-form for outer layer 36 for the wall structure, and wherein theso-prepared pre-form is wet with the epoxy resin which fillssubstantially all of the voids in the fiberglass substrate.

A plurality of closed-cell foam blocks, about 3 inches thick, 8 incheswide, and extending the full height of the set-up layer 36, are laid onthe set-up layer 36, parallel to each other, at spaced locations alongthe length of the panel. As used herein, height, length, and thicknessof a wall panel refers to the panel in its upright use orientation in anupright e.g. foundation wall or above-grade wall. “Width” refers to suchheight dimension of the construct while the construct is beingfabricated in the above-noted horizontal orientation. As the foam blocksare laid on the horizontal pre-form of the first layer, some of the webresin on the pre-form of the first layer transfers to the dry blocks offoam. In the alternative, one or more surfaces of the foam blocks can bepre-wetted with a desired amount of the curable resin. In any event, thefoam blocks, on the wet pre-form, bear a certain level of surface liquidin the form of curable resin.

A second wetted weaving layer pre-form, wetted with the same 2-partepoxy resin, is prepared in the same manner as the first outer layer,and is weaved back and forth over the combination of the outer layerpre-form and the foam blocks 32, with the wetted weaving layer weavingback and forth in face-to-face contact with the blocks and the layer 36pre-form, along the full overall surface of the respective construct,leaving elongate voids in the construct between the respective blocks.

A second set of a plurality of foam blocks 32, optionally pre-wettedwith the epoxy resin, is then inserted into the voids between the foamblocks which are already in the structure, thus filling in the entiretyof the length and the width of the layer 36 pre-form. Accordingly, thecombination of foam blocks 32 and weaving layer 50 pre-form present agenerally uniformly flat and continuous top surface of the resultingconstruct at this stage of assembly of the building panel, and all ofthe blocks, the layer 36 pre-form, and the layer 50 pre-form, are wetwith the epoxy resin.

A third wetted inner layer 34 pre-form is prepared in the same manner asthe first outer layer pre-form and the weaving layer pre-form, and islaid on top of, and pressed onto, the construct, such that the thirdlayer pre-form serves as a covering layer covering the entirety of thetop surface of the resulting construct. At this stage, the foam blocksare urged toward each other to consolidate the foam blocks and theweaving layer together.

Channel studs 123 can be pressed into, onto the construct at that timeif and as desired. Flanges 126 of the channel studs can be pre-coatedwith the epoxy resin, or can simply be pressed into the wetted surfaceof the layer 34 pre-form. In general, legs 128 and end panels 130 of thechannel studs remain dry, and are not coated with the epoxy resin. Aloading bar, loading belt, or other loading structure can optionally beapplied across the tops of the channel studs, at end panels 130,pressing the channel studs into the inner layer 34, and correspondinglyapplying a load in general tending to consolidate the building panel,top to bottom, including channel studs 123, inner layer 34 pre-form,foam blocks 32, weaving layer 50 pre-form, and outer layer 36 pre-form.

The construct is held in the so-assembled and consolidated conditionwhile the resin cures sufficiently to permanently fix the respectiveelements in the panel construct in their respective locations, therebyto form the resultant building panel 14.

In the resulting panel, the epoxy-resin impregnated 22-ounce fiberglasslayers develop cured fiber-reinforced polymeric layers which are about0.035 inch (0.9 mm) thick.

FIG. 25 illustrates such an exemplary and non-limiting wet laying methodby which building panels 14 of the invention can be made in a continuousprocess, and whereby the so-manufactured building panels can be cut toany desired length at the end of the manufacturing process. As seen inFIG. 25, a first unwind unwinds a roll 64 of a carrier web 66, forexample a layer of MYLAR®, and feeds the carrier web to a processingline 68. The carrier web traverses the processing line, carrying variouswork pieces along the processing line as the building panel isfabricated and hardened. Carrier web 66 is separated from the cured workpieces, work product, at a point after the so-manufactured buildingpanel product has cured sufficiently to be dimensionally stable. Afterthe carrier web is separated from the cured work pieces, the carrier webis wound up on a wind-up roll 70.

A first layer of fiberglass substrate 72 is unwound from a roll of suchmaterial and is fed generally downwardly through a pair of nip rolls 74which carry a puddle 76 of 2-part curable resin, and apply such resin tosubstrate 72, and squeeze such resin into substrate 72, as the substratepasses through the nip defined between rolls 74, thus to develop aprogressively resin-impregnated outer layer 36 pre-form. The wettedpre-form is carried across one or more guiding rolls downwardly and ontocarrier web 66, and wherein the carrier web and theprogressively-impregnated outer layer 36 pre-form are travelling atapproximately the same speed along processing line 68.

Still referring to FIG. 25, a first stack 86A of foam blocks 32 providesa supply of foam blocks. The foam blocks are placed on the outer layer36 pre-form at spaced locations. The foam blocks extend the full widthof the outer layer 36 pre-form. The blocks as illustrated are 8 incheswide and are spaced about 8 inches from each other by voids 84, on thelayer 36 pre-form. Foam blocks 32 may or may not be pre-wetted withcurable resin, as desired.

A second layer of fiberglass substrate 78 is unwound from a roll of suchsubstrate material and is fed vertically downwardly through a pair ofnip rolls 80 which carry a puddle 82 of 2-part curable resin, and applysuch resin to substrate 78, and squeeze such resin into substrate 78, asthe substrate passes through the nip defined between rolls 80, thus todevelop a resin-wetted weaving layer 50 pre-form. The wetted pre-form iscarried across one or more guiding rolls downwardly and onto the outerlayer 36 pre-form and blocks 32, and wherein the weaving layer pre-form,as it approaches the construct on the carrier web, is travelling at aspeed which is faster than the speed of travel of outer layer 36 andfoam blocks 32, and which is consistent with weaving the weaving layerinto the entirety of the upper surface of the construct, including theupper surface of the outer layer 36 pre-form, the upper surfaces ofblocks 32, and the side surfaces of blocks 32 which extend away from andtoward the outer layer 36 pre-form.

The weaving layer pre-form thus lies in intimate contact with allpreviously-exposed surfaces of the underlying construct. The resultingconstruct has no substantial voids, no substantial air pockets betweenthe weaving layer and the outer layer 36 pre-form, or between theweaving layer and the foam blocks, which cannot be eliminatedsubsequently in the process. The weaving layer then forms the entiretyof the top surface of the resulting intermediate construct. Theresulting intermediate construct defines channels extending along thewidth of the construct, as viewed into the paper in FIG. 25. Restated,the voids 84 between foam blocks 32 at the left side of FIG. 25 remainvoids; while the voids have been lined with the weaving layer 50pre-form.

The voids 84 are then filled with additional foam blocks 32 from asecond stack 86B of such foam blocks. The foam blocks may or may not bepre-wetted with curable resin, as desired. After the blocks are inplace, the voids 84 have been completely filled by the foam blocks,resulting in a generally flat, and continuous, surface as illustrated inFIG. 25 to the right of the second stack 86B of foam blocks.

A third layer of fiberglass substrate 88 is unwound from a roll of suchmaterial and is fed generally downwardly through a pair of nip rolls 90which carry a puddle 92 of 2-part curable resin, and apply such resin tosubstrate 88, and squeeze such resin into substrate 88, as the substratepasses through the nip defined between rolls 90, thus to develop aresin-wetted inner layer 34 pre-form. The wetted pre-form is carriedacross one or more guiding rolls downwardly and onto the top surface ofthe underlying resin-wetted construct, and wherein the inner layer 34pre-form and the underlying construct, as carried by the carrier web 66,are travelling at approximately the same speed along processing line 68.

After the inner layer 34 pre-form has been applied to the construct, theresin-wetted inner layer pre-form covers the entirety of the width ofthe top surface of the construct. Channel studs 123 are then optionallyapplied to the construct, along the width of the construct, at spacedlocations along the length of the construct, consistent with the desiredspacing of the studs from each other in the finished building panels.

As desired, a weighting or other downwardly-directed force can beapplied to the channel studs to assist the channel studs in becomingwetted with the resin which is contained in the inner layer 34 pre-form,and to urge the studs into intimate and bonding contact with the innerlayer 34 pre-form. Such load can be applied to each channel stud by aloading structure which is distinct for each stud. In the alternative, aloading structure such as a plate or a belt can be applied to multiplestuds, thus bridging the spaces between the respective studs. Suchloading structure can take the form of, for example and withoutlimitation, a loading belt. As desired, the load can be applied to theentire surface of the construct in order to further urge resin intoremaining voids. As a result of the loading, the number and size of anyremaining voids is sufficiently reduced such that any remaining voidsare of little or no consequence to the strength of the overallconstruct.

In the alternative, or in addition, more resin can be applied to thebottom surfaces of flanges 126 of the channel studs, thus to facilitatewetting contact between the stud flanges and the inner layer pre-form.

Once the inner layer pre-form is applied to the construct, and with thechannel studs applied according to design, if studs are used, theso-formed construct is passed through a curing oven 94 or other curingprocess, as needed, thus to cure the curable resin. As the resin cures,it sets up, also known as hardening. The chemical concept is that thereactable moieties, in the curable resin components, react to form longchain polymers, with a substantial increase in molecular weight, whichresults in the transformation of the reacting materials from the liquidform to what is known generally as a solid plastic; thus generallyfixing the dimensions of the reaction products such that the reactionproducts are dimensionally stable, and making the resultant panel intothe stiff and rigid fiber-reinforced product which is desired forbuilding panels 14.

As the reacted, hardened, construct emerges from the curing process, theconstruct/product is sufficiently rigid, stiff, durable, dimensionallystable as to have no further need for carrier web 66, whereby carrierweb 66 is stripped away from the construct/product and wound up onwind-up roll 70.

An additional layer can be added between carrier web 66 and outer layer36, for example as an appearance layer to enhance the appearance of theouter surface of the resultant building panel. Such layer can be addedas e.g. a gel coat, or as a pre-formed layer. As a pre-formed layer,such layer can be used in place of carrier web 66; such additional layerbecoming part of the so-manufactured building panel product. In suchinstance, the additional layer is installed at unwind roll 64 instead ofthe MYLAR material, and wind-up 70 is no longer needed.

In the alternative, or in addition, and still referring to FIG. 25, agel coat layer or other appearance layer can be added on top of innerlayer 34, optionally on top of channel studs 123, to provide a desiredappearance to the inner surface of finished building panel 14.

The product made according to the process illustrated in FIG. 25 can bea continuous-length product. Edge trim saws 96 on opposing edges ofprocessing line 68 trim the edges of the construct to obtain a resultantdesired width of the construct. A cut-off saw 98 extends transverselyacross the processing line. Saw 98 is used to periodically make atransverse cut across the so-produced construct, thus to cut offbuilding panels, from the continuously-produced construct, at desiredlengths.

Still reflecting on the machines and processes illustrated and describedwith respect to FIGS. 8 and 25, another embodiment of building panels ofthe invention is illustrated in FIG. 26, and an exemplary process formaking such building panel is illustrated in FIG. 27.

Turning now to FIG. 26, outer layer 36 weaving layer 50, and foam blocks32 are the same materials, the same structures, and in the same relativepositioning as in FIG. 8. The primary difference between the embodimentof FIG. 8 and the embodiment of FIG. 26 is that studs 123 are positionedbetween weaving layer 50, at locations remote from outer layer 36, andinner layer 34. In such structures, studs 123 are held in the assemblyby the entrapment of the studs 123 between weaving layer 50 and innerlayer 34. Any adhesion between studs 123 and the weaving layer canoperate to further hold, and fix, the position of studs 123 in theassembly. Location of studs 123 is illustrated in FIG. 26 as being onweaving layer 50 such that the weaving layer is between a foam block andthe inner layer.

FIG. 27 illustrates a method by which building panels 14, as illustratedin FIG. 26, can be made in a continuous process, similar to the processillustrated in FIG. 25. As seen in FIG. 27, a first unwind unwinds aroll 64 of a carrier web 66, for example a layer of MYLAR®, and feedsthe carrier web to processing line 68. The carrier web traverses theprocessing line, carrying various work pieces along the processing lineas the building panel is fabricated and hardened, and is separated fromthe cured work pieces, work product, at a point after theso-manufactured building panel product has cured sufficiently to bedimensionally stable. After the carrier web is separated from the curedwork pieces, the carrier web is wound up on a wind-up roll 70.

A first layer of fiberglass substrate 72 is unwound from a roll of suchmaterial and is fed generally downwardly through a pair of nip rolls 74which carry a puddle 76 of 2-part curable resin, and apply such resin tosubstrate 72, and squeeze such resin into substrate 72, as the substratepasses through the nip defined between rolls 74, thus to develop aprogressively resin-impregnated outer layer 36 pre-form. The wettedpre-form is carried across one or more guiding rolls downwardly and ontocarrier web 66, and wherein the carrier web and theprogressively-impregnated outer layer 36 pre-form are travelling atapproximately the same speed along processing line 68.

Still referring to FIG. 27, a first stack 86A of foam blocks 32 providesa supply of foam blocks. The foam blocks are placed on the outer layer36 pre-form at spaced locations. The foam blocks extend the full widthof the outer layer 36 pre-form. The blocks as illustrated are 8 incheswide and are spaced about 8 inches from each other on the layer 36pre-form, with voids 84 between the respective blocks. Foam blocks 32may or may not be pre-wetted with curable resin, as desired.

A second layer of fiberglass substrate 78 is unwound from a roll of suchsubstrate material and is fed vertically downwardly through a pair ofnip rolls 80 which carry a puddle 82 of 2-part curable resin, and applysuch resin to substrate 78, and squeeze such resin into substrate 78, asthe substrate passes through the nip defined between rolls 80, thus todevelop a resin-wetted weaving layer 50 pre-form. The wetted pre-form iscarried across one or more guiding rolls downwardly and onto the outerlayer 36 pre-form and blocks 32, and wherein the weaving layer pre-form,as it approaches the construct on the carrier web, is travelling at aspeed which is faster than the speed of travel of outer layer 36 andfoam blocks 32, and which is consistent with weaving the weaving layerinto the entirety of the upper surface of the construct, including theupper surface of the outer layer 36 pre-form, the upper surfaces ofblocks 32, and the side surfaces of blocks 32 which extend away from andtoward the outer layer 36 pre-form.

The weaving layer pre-form thus lies in intimate contact with allpreviously-exposed surfaces of the underlying construct. The resultingconstruct has no substantial voids, no substantial air pockets betweenthe weaving layer and the outer layer 36 pre-form, or between theweaving layer and the foam blocks, which cannot be eliminatedsubsequently in the process. The weaving layer then forms the entiretyof the top surface of the resulting intermediate construct. Theresulting intermediate construct defines channels extending along thewidth of the construct, as viewed into the paper in FIG. 25. Restated,the voids 84 between foam blocks 32 at the left side of FIG. 25 remainvoids; while the voids have been lined with the weaving layer 50pre-form.

The voids 84 are then filled with additional foam blocks 32 from asecond stack 86B of such foam blocks. The foam blocks may or may not bepre-wetted with curable resin, as desired. After the blocks are inplace, the voids 84 have been completely filled by the foam blocks,resulting in a generally flat, and continuous, surface as illustrated inFIG. 27 to the right of the second stack 86B of foam blocks. At thisstage, the foam blocks are urged toward each other to consolidate thefoam blocks and the weaving layer together.

Channel studs 123 are then applied to the construct, along the width ofthe construct, at spaced locations along the length of the construct,consistent with the desired spacing of the studs from each other in thefinished building panels. In the embodiment illustrated in FIG. 26,studs 123 are positioned on weaving layer 50 at locations where theweaving layer is remote from outer layer 36.

A third layer of fiberglass substrate 88 is unwound from a roll of suchmaterial and is fed generally downwardly through a pair of nip rolls 90which carry a puddle 92 of 2-part curable resin, and apply such resin tosubstrate 88, and squeeze such resin into substrate 88, as the substratepasses through the nip defined between rolls 90, thus to develop aresin-wetted inner layer 34 pre-form. The wetted pre-form is carriedacross one or more guiding rolls downwardly and onto the top surface ofthe underlying resin-wetted construct. The speed of layer 34 isaccelerated relative to the speed of travel of the underlying construct,whereby layer 34 is applied over studs 123 such that the full strengthof layer 34, when cured, holds the studs in their designated locationsin the completed wall structure.

After the inner layer 34 pre-form has been applied to the construct, theresin-wetted inner layer pre-form covers the entirety of the width ofthe top surface of the construct, including covering studs 123.

By positioning studs 123 over those portions of the weaving layer whichare remote from outer layer 36, the weaving layer and the inner layerreinforce each other adjacent studs 123, whereby the coordinatedlocations of the weaving layer, the inner layer, and the studs providecooperative and cumulative bending strength/resistances to externalforces which are directed inwardly into the building.

Once the inner layer is cured as at curing station 94, the configurationof the inner layer adjacent the studs 123 permanently takes on generallythe same configuration as the studs. Accordingly, the strengthcharacteristics taught above for studs 123 are much less important inembodiments represented by FIG. 27, whereby the structure and/ormaterials from which studs 123 are made still can, but need not, providesubstantial structural strength to the building panel. Rather, suchstrength is available from inner layer 34. In such structures, studs 123can be made from, for example and without limitation, blocks of foamedpolystyrene, polyurethane, or other foamed polymer, or other relativelylower cost material of choice, so long as the structural strength of thestuds is sufficient to support the desired structure and lay of innerlayer 34 in its pre-form state and until such time as inner layer 34 hasbeen cured.

Another embodiment of building panels of the invention is illustrated inFIG. 28. In the embodiment of FIG. 28, each foam block 32 is wrapped inone or more layers 190 of resin-impregnated fiberglass which closely andintimately wraps the longitudinally-extending outer surfaces of theblock, optionally the entirety of the longitudinally-extending outersurfaces of the block.

The resin may be added to the wrapped fiberglass layers on one or moresides of the foam blocks before the foam blocks are introduced into theprocess of assembling building panels of the invention. Such pre-addedresin in the wrapped fiberglass layers may be cured prior to assembly ofthe foam blocks into a panel. In the alternative, the resin may be curedlater, along with the curing of the resin in the inner and outer layers.

In the alternative, the entirety of the resin used to consolidate thewrapping layers and bond the wrapping layers to the foam can be addedto, dispersed in, the fiberglass layers of the foam blocks after thefoam blocks have been assembled with some or all of the remainingelements of the panel structure.

The fiberglass in a wrapping layer can be applied as a winding ofoverlapping strands of fiber in a pattern which extends along the lengthof a given block of foam. In the alternative, the fiberglass can be apre-woven matt of fiberglass which is wrapped about the foam block so asto form e.g. a butt joint or an overlapping joint where the ends of thewrap layer meet.

Whether the wrapping layer is applied as a winding of overlappingstrands or as a woven fabric, the wrapping layer can represent an openpattern where some of the foam surface is exposed to casual visualobservation through openings in the wrapped pattern. In the alternative,the wrapping layer can represent a closed pattern where the fiberglassstrands visually obscure substantially all of the underlying surface ofthe foam block.

Given the presence of the wrapping layers, weaving layer 50 is not used.

An exemplary process for making building panels of FIG. 28 is e.g. avacuum infusion process, illustrated in FIG. 29. In FIG. 29, upper andlower layers of the vacuum bag are illustrated as 192A and 192Brespectively, and where the bag is still open for assembling of elementsof the structure being fabricated. As suggested in FIG. 29, one or morelayers of fiberglass pre-form, which will become outer layer 36, arelaid out on the lower layer 192B of the vacuum bag. Then the foam blocks32, pre-wrapped in layers 190, are laid side-by-side on the outer layerpre-form. Next, and optionally, pre-formed and cured studs 123 are addedon top of the wrapped foam blocks. One or more layers of fiberglasspre-form, which will become the inner layer 34, are laid over the top ofthe resulting subassembly, along with any desired resin distributionlayer. The vacuum bag is then closed, vacuum is drawn and resin isadmitted into the bag, whereby the resin penetrates voids in thefiberglass layers, and voids between surfaces of layers 190, and iscured in the bag according to conventional vacuum infusion practice offilling resin into the bag and curing such resin in the bag; wherebylayers 34 and 36, wrapped blocks 32, and studs 123, are all joinedtogether as a unitary composite structure.

In some instances, the wrapping layers 190 are not resin-filled beforethe vacuum-infusion process, whereby the resin which enters the bagduring the vacuum infusion processing fills the voids in the wrappinglayers as well as the voids in the layer 34 and 36 pre-forms. In otherinstances, the wrapping layers 190 have already been filled with resin.In some instances, the resin has been cured, in which case the resinintroduced in the vacuum infusion process serves to adhere therespective wrapped blocks to each other, as well as to permeate theinner and outer layer pre-forms thereby consolidating all of therespective components into a unitary composite structure. In othercases, the resin has not been cured, in which case the resin introducedin the vacuum infusion process serves both to adhere the blocks to eachother and to the inner and outer layers, and to fabricate the blocks andthe inner and outer layers into a single unitary structure. In any suchstructure, the portions of the resin-impregnated wrapping layers whichtraverse between the inner and outer layers function as structurallyreinforcing layers in the resulting building panel.

FIG. 30 illustrates yet another embodiment of building panels of theinvention. In the embodiment illustrated in FIG. 30, the foam blocks 32are pre-wrapped by fiberglass layers 190, the same as the pre-wrappingdiscussed above with respect to FIG. 29. Thus, fiberglass layers 190 arepre-wrapped about the foam blocks, and optionally cured, before the foamblocks are assembled into the building panel. Contrary to the FIG. 29structure, in the structure illustrated in FIG. 30, no channel studs 123are used to reinforce the building panel. Rather, every third foam blockis oriented 90 degrees such that the narrower edges 198 of therespective wrapped foam block elements are oriented toward the inner 34and outer 36 layers. Thus, in FIG. 30, foam blocks 32B, 32E, and 32Hform a second set of foam blocks which are so oriented. The remainingfoam blocks, e.g. 32A, 32C, 32D, 32F, 32G, and 321 represent the firstset of foam blocks.

Blocks 32B, 32E, and 32H thus perform as structurally-reinforcingmembers, previously illustrated as studs 23 and 123, and are hereinafterreferred to as studs.

In the first set of foam blocks/elements, the relatively wider sides 199of the foam elements face toward the inner and outer layers. In thesecond set of foam elements, the relatively wider sides 199 of the foamelements face along the length of the building panel.

In some embodiments, and depending on the specifications requiring thatstructural strength be contributed by the structurally-reinforcing foamstuds 32C, 32F, the density of the foam in the reinforcing foam studsillustrated as 32B, 32E, and 32H can be greater than the density of thefoam in the remaining foam blocks, in order to achieve the desired levelof structural reinforcement. In other implementations of FIG. 30, thestructural requirements of the foam studs 32B, 32E, and 32H arerelatively less, such that the foam density in foam studs 32B, 32E, and32H can be the same as the density in the remaining foam blocks. In yetother implementations, the foam density in foam studs 32B, 32E, and 32Hcan be less than the density in the remaining foam blocks. Thus, thefoam density can be specified as an element in achieving the desiredlevel of strength which is contributed by the rotated foam block studs32B, 32E, and 32H.

In the alternative, or in combination, such reinforcement strength canbe captured according to the thickness and rigidity of the wrappinglayers 190 about the respective foam block studs 32B, 32E, and 32H. Insome implementations, the wrapping layers 190 about foam block studs32B, 32E, and 32H are the same as the wrapping layers 190 about theremaining foam blocks. In other implementations, the wrapping layers 190about foam block studs 32B, 32E, and 32H are thicker or otherwise morerigid than the layers 190 about the remaining foam blocks, in order toachieve greater levels of strength and rigidity in the studs.

In light of the pre-wrapped structure of foam blocks 32, thefiberglass-reinforced wrapping layer 190 can serve the functions ofeither or both of inner layer or outer layer 36, whereby layers 34 and36 are optional elements of the building panel of FIG. 30.

In any event, the strength provided in the reinforcing block studs 32B,32E, and 32H can be manipulated by selectively specifying both the foamdensity in the respective blocks and the thickness and othercharacteristics of the fiberglass reinforced wrapping layers 190.

Given the structural orientation of foam blocks 32 in FIG. 30, desirablewidth and thickness dimensions for the wrapped foam blocks, includingthe foam block studs, including the wrapping layers 190, are 6.5 incheswidth and 3.0 inches thickness. Such dimensions provide a commonly-useddepth “T1” of space 131 between the studs, of about 3.5 inches, assumingthat the thickness of the inner layer 34 is negligible. The illustratedstructure, and again assuming negligible thickness of inner layer 34,also provides a commonly-used center-to-center distance “T2” between thefoam block studs of 16 inches.

Given the above dimensions, the size of space 131 between a pair ofadjacent studs is the same as conventional depth, namely 3.5 inches ofconventional wood stud spacings, and a width of 13 inches. Further, the16 inch center-to-center spacing of the foam block studs provides forconventional attachment of conventional building materials such as48-inch wide sheeting 129 on the inside of the building panel. Thus, theembodiment of FIG. 30 provides an interface at the inner surface of thebuilding panel to which conventional materials can be mated, joined,using conventional attachment technology and conventional dimensions.

The embodiment of the building panel illustrated in FIG. 30 can befabricated according to a process similar to that illustrated in FIG.25. Starting with the process illustrated in FIG. 25, studs 123 areomitted and the weaving layer is omitted. The first stack of foam blocksplaces 2 blocks side-by-side on the outer layer precursor. The secondstack of foam blocks is oriented so as to place the foam blocks on edges198 rather than on sides 199.

The embodiment of FIG. 30 can also be made by the above-mentioned vacuuminfusion process, and wherein wrapping layers 190 may or may not bepre-infused, in whole or in part, and may or may not be pre-cured whenplaced in the vacuum infusion process.

Pre-wrapped foam blocks 32 in the FIG. 30 embodiments can be replaced byother structurally-reinforcing structures, such as the studs 23 of FIG.6. Another replacement structure is a pultruded stud having walls about0.018 inch thick to about 0.50 inch thick. By engineering thethicknesses of the walls of the pultruded stud, the 3-inch width of thereinforcing members can be reduced, such as to 1.5 inches, withcorresponding increase in widths of the laid-flat foam blocks, wherebythe width of the resulting cavity 131 is 14.5 inches.

Or by wrapping the foam block 32 in additional layers, or thickerlayers, of fiberglass-reinforced resin, the strength contribution of thefiberglass wrapping can be increased sufficiently to enable the width ofthe foam block to be reduced to 1.5 inches, whereupon the width ofcavity 131 is again 14.5 inches.

As desired, the width of a stud 23 or a stud 123 can be greater than 3inches, such as 4 inches, 5 inches, or 6 inches, with correspondingadjustment in the widths of the laid-flat foam blocks to achieve adesired center-to-center spacing of the foam blocks such as 16 inchescenter-to-center or 24 inches center-to-center.

FIG. 31 illustrates yet another structure for the fiber reinforcedpolymeric building panels of the invention. In FIG. 31, a series offiberglass reinforced layer elements 200 collectively function in thecapacities earlier described for inner layer 34, outer layer 36, andweaving layer 50. Each layer element 200 extends

-   -   (i) from a first end 202 thereof adjacent a first        outwardly-facing side 204 of a first foam block along the        outwardly-facing surface 205 of a second foam block to a second        side 206 of the second foam block in place of outer layer 36,    -   (ii) thence extends between that second side 206 of the second        block and a first side 208 of a third foam block as a        reinforcing member 209, in place of weaving layer 50, to the        inwardly-facing sides 210 of the second and third blocks,    -   (iii) thence extends along the inwardly-facing side 210 of the        third foam block in place of inner layer 34, to an        inwardly-facing side of a fourth foam block and to a second end        212 of the layer 200 adjacent the inwardly-facing side 210 of        the fourth foam block.

The first 202 and second 212 ends of a given layer element 200 overlapthe adjoining layer elements 200 at the reinforcing members 209, wherebyeach layer element overlies or underlies three of the reinforcingmembers 209 and reaches proximity to four of the foam blocks.

The depiction of the layers and layer elements in FIG. 31 is exaggeratedto show the layering. In actual structures, the overlapped end portionsof a given layer element 200 are generally received into the underlyingportions of the adjacent layer elements 200, with modest deformation ofthe underlying foam block, so as to form a relatively flat main innersurface 25 and a relatively flat outer surface 56. Thus, in the FIG. 31embodiment, each of inner layer 34 and outer layer 36 are constructedfrom portions of multiple layer elements.

Studs 123, as illustrated, are optionally added as desired in theembodiments of FIG. 31.

Now speaking generically of the invention, fiberglass layers used in theinvention, such as and without limitation, layers 34 and 36, can also bemade using the well-known chop spray method. In the chop spray method, alayer of fibers is sprinkled or sprayed onto a substrate, and are thencovered with a spray of resin. The resin impregnates the sprayed layerof fibers and is cured, thus to develop the respectivefiberglass-impregnated layer.

For example, the chop spray method, or any other known method offabricating fiberglass panels, can be used to fabricate outer layer 36and inner layer 34. Such inner and outer layers can then be broughttogether with e.g. the pre-wrapped foam blocks to do the final assemblyusing either additional resin or suitable construction adhesive. Studs123 can be added as desired on the outer surface of inner layer usingeither hardenable resin or construction adhesive.

As an alternative, the inner layer, the outer layer, and the weavinglayer can be pre-manufactured as hardened layers of resin-impregnatedfiberglass. The pre-manufactured weaving layer is in the configurationshown in e.g. FIG. 8. Foam blocks are optionally added to the cavitieson both sides of the weaving layer. The weaving layer, the inner layer,the outer layer, and the foam blocks, if used, are then joined to eachother using either additional flowable resin or construction adhesive,or a combination of adhesive and resin, optionally in a vacuum process,optionally a vacuum infusion process.

FIG. 32 shows yet another embodiment of building panels of theinvention. Inner layer 34 and outer layer 36 are as discussed earlierwith respect to e.g. FIG. 8. Foam blocks 32 are omitted. With the foamblocks omitted, the structurally-reinforcing member, illustrated earlierherein as weaving layer 50, can take on a wide variety ofconfigurations. The spaces between the structurally reinforcing memberelements are empty. For example, the structurally-reinforcing member canbe a polygonal e.g. honeycomb structure 194. While honeycomb layer 194can represent a wide variety of structures, the regular hexagonalstructure shown is believed to be highly cost effective in terms ofstrength per unit of mass of the honeycomb structure. The structuresurrounding a given cell/cavity 196 can be fabricated using a singlelayer of e.g. resin-impregnated fiberglass, or multiple layers ofresin-impregnated fibrous material. For example, and referring to FIG.32 specifically, the lower half of the honeycomb layer can be fabricatedusing a first such layer and the upper half can be fabricated using asecond such layer. A given cell 196 can span the full thickness of thespace between inner layer 34 and outer layer 36 as illustrated, or canspan less than the full thickness such as half of the thickness, orless, whereupon e.g. 2, or 3, or more cells can be used to span the fullthickness of the space between the inner and outer layers.

Cells 196 may or may not contain thermally insulating material such asclosed cell foam as is used in foam blocks 32 in others of theillustrated embodiments. Where insulating foam is used, an e.g.foam-in-place process can be used to install the foam into therespective cells.

As a further illumination of the empty-space embodiments represented byFIG. 32, the structurally-reinforcing member can be weaving layer 50such as illustrated in FIGS. 8 and 26, or a more robust embodiment ofsuch weaving layer 50, without inclusion of the insulating foam,illustrated as FIG. 33.

In the embodiment illustrated in FIG. 33, the width of stud 123, definedbetween legs 128, is 1.5 inches. Given a center-to-center “T2” distancebetween studs 123 of 16 inches, the width of space 131 between adjacentones of the studs is 14.5 inches, which corresponds to the conventionalwidth of commercially available panels of fiberglass batt insulation.

Further, the structurally-reinforcing member can be the wrapping layers190 illustrated in FIGS. 28, 29, and 30, again with the foam blocks 32omitted from the structure. Reflecting on both FIGS. 32 and 33, thespace between the inner and outer layers can be occupied by materialshaving a wide variety of other configurations which include, withoutlimitation, circles, ellipses, ovals and other arcuate figures,triangles, and other polygons, as well as a wide variety of corrugatestructures.

FIG. 34 shows a cross-section of a building panel of the inventionwherein inner layer 234 and outer layer 236, are integral with astructurally-reinforcing bridging member 250. Studs 123 can be used asoptional, for example to create a cavity 131 for running utilities or toadd insulation, or to further contribute to the strength of the buildingpanel. The building panel as illustrated in FIG. 34 can be made by, forexample, a continuous pultrusion process wherein the illustratedcross-section is representative of the product coming out of thepultrusion die. The pultruded product is produced continuously and cutat convenient lengths which represent the height of an upstandingbuilding panel used in e.g. a wall structure. The top and bottom cutends are covered by top and bottom plates as desired, whether in themanufacturing process or prior to installation at the construction site.

Given that the closed cavities 196 in the structure are empty, all ofthe strength in the structure is derived from structural elements 234,236, and 250. Thus, structural elements 234, 236, and 250 are designedas structural members in and of themselves, whereby inner layer 234,outer layer 236, and bridging member 250 have thicknesses relativelygreater than the thicknesses of layers 34, 36, and 50 in the embodimentsof e.g. s. Thicknesses of layers 234, 236, and 250, in the exampleillustrated in FIG. 34, can be, for example and without limitation,about 0.04 inch to about 0.5 inch for building panels which are to beused for typical residential or light commercial or light industrialconstruction.

Cavities 196 can be used as utility runs as desired. In any of thepultruded structures, cavities 196 can be filled with insulating foam orother known insulating materials, as desired, for example and withoutlimitation, by injecting the foam material as a latter stage of thepultrusion process. Any rigidity provided by such insulating material,if any, can be considered in designing especially the thicknesses ofelements 234, 236, and 250.

Exemplary structures of ends of the pultruded building panels, andjoinders of adjacent panels, are shown in FIGS. 34 and 34A. FIG. 34shows a male-female end combination on a building panel 14A. Each panelhas a male end 216 and a female end 218. FIG. 34 shows the male end 216of panel 14A joined to, received into, the female end 218 of a secondpanel 14B. FIG. 34A shows end joinder structure where both ends 220 of apanel define a first step 222A, 222B and a second step 224A, 224B, eachpanel having the same end structure at both ends, and all panels havinga common end structure. In FIG. 34A, end 220A of panel 14A is joinedwith end 220B of panel 14B.

FIG. 34B shows first and second pultruded panels 14A, 14B, similar tothe panels illustrated in FIGS. 34 and 34A, including bridging members250. In FIG. 34B, each panel has a plain end 220A and a receiving end220B. A reinforcing stud 123 is integral with the receiving end 220B.The plain end 220A of second panel 14B abuts against, and is joined to,the receiving end 220B of the first panel 14A in making a wallstructure, ceiling structure, or floor structure; and inner layer 234 ofthe second panel 14B abuts, against and is joined to, theoutwardly-facing surface 226 of stud 123 on the adjacent panel 14A.

So long as the panels are not cut, the panels can be joined end-to-endusing end structures which have been fabricated as part of the processof initially fabricating the panel. Where an initially-fabricated endstructure of a panel is cut off, such as at the construction site, thecut-off end of that panel can be joined to another panel using an “H”bracket 140.

FIG. 35 illustrates a building panel made using a series of laid-flatindividually-wrapped foam blocks 32 in combination with spaced hollowpultruded studs 123. An outer layer extends along the bottom of thestructure illustrated. An inner layer 34 extends along the top of thestructure illustrated, and overlies both the foam blocks and the studs.A given stud 123 extends from a closed end wall 126 at outer layer 36,along legs 128, past the main inner surface 25 of the panel at innersurfaces of blocks 32, and passes further inwardly of blocks 32 and awayfrom outer layer 36, to end panel 130. The end panel 130 of each stud isdisplaced about 1 inch to about 5.5 inches from inner surface 25, so asto define spaces 131 between the studs. Such stud can be made byapplying resin to a fabricated fiberglass layer and curing the resin. Inthe alternative, such stud can be made by a pultrusion process.

An inner layer of fiberglass-reinforced polymer is applied over both thelaid-flat blocks 32 and studs 123.

A hollow space 133 is defined inside each such stud. Hollow space 133can be filled with thermally-insulating foam as desired. The panelillustrated in FIG. 35 is thus a combination of foam blocks 32 wrappedin fiber-reinforced polymeric layers, and hollow studs 123. Where studs123 are pultruded studs, the panel represents a combination of pultrudedstuds and wrapped foam blocks.

FIG. 36 illustrates a building panel made using a series of laid-flatindividually-fabricated rectangular fiberglass-reinforced polymericpultruded blocks 232 in combination with spaced hollow pultruded studs223. Each stud 223 has a closed end wall 126 at outer layer 36, andextends along legs 128, past the main inner surface 25 of the panel atinner surfaces of the laid-flat pultrusions 232 and away from outerlayer 36, to end panel 130. The end panel 130 of each stud is displacedabout 1 inch to about 5.5 inches from inner surface 25, so as to definespaces 131 between the studs. A pultruded reinforcing web 238 extendsacross the stud proximate, optionally generally in alignment with, themain portion of the inner surface 25 of the panel.

Both pultruded blocks 232 and pultruded studs 223 are illustrated withhollow spaces 133. In another embodiment, not shown, insulating foam,for example polyurethane foam, is injected into the hollow spaces in oneor both of blocks 232 and studs 223, providing enhanced thermalinsulation characteristics.

FIG. 37 illustrates a vacuum molding process which can be used to makebuilding panels of the invention. FIG. 38 illustrates a building panelmade by such vacuum molding process.

Referring to FIGS. 37 and 38, a specific example of a process of makinga building panel of the invention is described in some detail. In FIG.37, the numeral 300 represents a lower female mold element whichincludes a plurality of elongate female recesses 302 spaced e.g. 16inches apart center-on-center. Numeral 306 represents the upper moldelement.

At the beginning of the process, the upper and lower mold elements,including recesses 302, are optionally coated with mold releasematerial. In the alternative, a mold release agent can be incorporatedinto the resin. Next, foam stud blocks 323, pre-wrapped with layers 308of fiberglass, are placed into recesses 302. Foam stud blocks 323 andrecesses 302 are so sized and configured that the foam blocks fit snuglyin the recesses, and the top surfaces of the foam stud blocks aregenerally co-planar with the upper surface 304 of the lower moldelement.

As part of the process of placing the foam stud blocks into therecesses, each foam stud block is drawn through a resin wetting machinewhich applies coatings of liquid resin on three of the four elongatesurfaces of the foam block. The three surfaces which are coated are thebottom surface and the two side surfaces, as indicated by arrows 310 inFIG. 37. Thus, the three surfaces of stud blocks 323 which are receivedagainst surfaces of the lower mold element are coated with liquid resin,leaving the top surfaces 311 of the stud blocks uncoated and dry. Thus,the upper surface of the assemblage at this stage of the assemblyprocess, comprising the upper surface 304 of the lower mold element andthe top surfaces 311 of the stud blocks, is generally free from liquidresin.

Next, a dry layer 334 of 22 ounce fiberglass fabric, which will becomethe inner layer of the so-fabricated building panel, is unrolled from aroll of such material mounted adjacent e.g. the right end of the moldtable as illustrated in FIG. 37 and is pulled over the lower moldelement, from the right side to the left side. Since the upper surfaceof the assemblage is generally free from resin, the fabric layer can beeasily pulled and dragged over the top surface of the assembly. Thelayer of dry fabric is laid over the entirety of the length and width ofthe lower mold element, including over the top surfaces of stud blocks323.

Next, foam blocks 332, pre-wrapped with layers 314 of fiberglass, arelaid flat on top of the dry fabric, edge-to-edge as illustrated in FIG.37. As part of the process of placing the laid-flat foam blocks 332 ontothe dry fabric, each foam block 332 is first coated on two, optionallythree, of its four elongate surfaces with a coating of liquid resin. Thetwo surfaces which are necessarily coated are the bottom surface 316 andeither the left side surface 318 or the right side surface 320, both asillustrated in FIG. 37. FIG. 37 illustrates the bottom surface and theleft side surface as being coated, as indicated by arrows 312 in FIG.37. Optionally, the right side surface can also be coated with resin atthe same time.

Thus, by the time all the blocks 332 have been laid onto dry layer 334,a layer of resin has been placed over the entirety of the top surface oflayer 334, by the resin on the bottom surfaces of blocks 332. Inaddition, the resin applied to the one or more side surfaces of the foamblocks readily transfers in part to the facing side surfaces of theadjacent foam blocks. Or if both the right and left side surfaces offoam blocks 332 have been resin-coated, then the coatings on the facingside surfaces merge and cooperate with each other. As part of theprocess of placing foam blocks 332 on layer 334, and if only one sidesurface of the blocks 332 is being coated with resin, theotherwise-uncoated side surface of the terminal end ones of the foamblocks is coated with resin on both side surfaces, whereby theoutwardly-facing side surface of the last-placed foam block 332 is alsocoated with resin.

At this stage of the process, foam blocks 332 collectively form a dryupper surface 324 of the assemblage of elements, generally free fromliquid resin. Next, another dry layer of the 22 ounce fiberglass fabric,which will become the outer layer 336 of the so-fabricated buildingpanel, is unrolled from the roll of such material mounted adjacent e.g.the right end of the vacuum table and is pulled over the dry laid-flatfoam blocks 332, from the right side of mold 300 to the left side of themold. Since the upper surfaces of foam blocks 332 are generally freefrom resin, the fabric layer can be easily pulled and dragged over thetop surface 324 of the foam blocks, which form the top surface of theassembly at this stage. Layer 336 of dry fabric is laid over theentirety of the assemblage of foam blocks 332, whereby layer 336 becomesthe top surface of the assemblage.

Resin is then applied to the top surface of layer 336, such as by a dripcoating, a roll coating, a liquid curtain coating, or other knownsurface-coating process, providing a resin coating over the entirety ofthe top surface of the assemblage. At this stage of the assembly, all ofthe bottom and side surfaces of foam blocks 323 and 332 are coated withliquid resin, and the top surfaces are uncoated with resin. In the caseof foam blocks 323, inner layer 334 is next adjacent the dry top surfaceof foam blocks 323, and a layer of resin is located at the top surfaceof inner layer 334, whereby the dry top surfaces of foam blocks 323 areseparated from resin by only inner layer 334.

In the case of foam blocks 332, outer layer 336 is next adjacent the drytop surface 324 of foam blocks 332, and a layer of resin is located atthe top surface of outer layer 336, whereby the dry top surfaces of foamblocks 332 are separated from resin by only outer layer 336.

The upper and lower mold elements are then brought together, with a sealtherebetween, so as to form a closed and sealed mold, with therespective elements of the building panel in the mold cavity.

The mold cavity is then evacuated, drawing a vacuum which removessubstantially all of the air out of the cavity. As the air is withdrawnfrom the cavity, the resin flows to all areas of the mold where air hasbeen removed, including through layers 334 and 336, thus to fill in allvoids left by the evacuating air and to form a continuous resin matrixabout and through all of layers 334, 336, and the wrapping layers 308and 314 of fiberglass which encompass foam blocks 323 and 332.

Thus, resin flows downwardly through layer 334 and into intimate bondingcontact with the top surfaces of foam blocks 323. Resin also flowsdownwardly through layer 336 and into intimate bonding contact with thetop surfaces of foam blocks 332. As a result, the resin in the moldflows to all areas which have been evacuated by the removed air, thuscreating a continuous matrix of resin throughout the structure in all ofthe fiberglass layers. However, in instances where the foam in foamblocks 323 and 332 is a closed cell foam, the resin does not penetrategenerally beyond the outer surfaces of the foam blocks. Where the foamis an open-cell foam, the resin can penetrate more deeply into the foamblocks as permitted by the permeability of the foam.

Once the mold has been closed and evacuated, the resin is cured in themold. In the process of curing the resin, the mold may be heated, ornot, depending on the thermal requirements associated with the curing ofthe specific resin being used. Where heat is required, heat is applied.Where heat is not required, the resin is typically cured at ambienttemperature.

After curing, the cured fiber-reinforced polymeric building panelproduct is removed from the mold. The mold is cleaned if and as needed,and the process is repeated to make another building panel.

FIG. 38 illustrates a building panel made according to the processdescribed with respect to FIG. 37. The process of FIG. 37 can be used tomake building panels which are cost effective in use of materials at thepoints of stress, which are readily combined with conventional buildingmaterials using conventionally-recognized and standardized buildingelements spacings. Thus, in the embodiment illustrated, foam blocks 332,including the wrapping layers and resin, are 9 feet long, 8 inches wide,and 3 inches thick between layers 334 and 336. Stud blocks extend 3inches from layer 334, and are 2 inches wide, and are 9 feet long.Layers 334 and 336 are 9 feet wide and as long as the length of thepanel. Layers 308, 314, 334, and 336 are all made of the same 22 ouncefiberglass fabric and are thus all the same thickness when filled withresin. The resulting thickness of each such layer is about 0.035 inch(0.9 mm). In the given structure, outer layer 336 plus the adjacentportion of wrapping layer 314 is thus uniformly 0.070 inch (1.8 mm)thick. Similarly, inner layer 336 plus the adjacent portion of wrappinglayer 314 is uniformly 0.070 inch (1.8 mm) thick. Also, the collectivethickness of the reinforcing portions 209 of the wrapping layers betweeneach pair of foam blocks 332 is 0.07 inch (1.8 mm). The outer surface ofthe building panel is stressed by side loading and water pressure. Theinner layer is stressed in tension by the side loading. The reinforcingportions are stressed both by side loading and compression loading.Thus, all of the highly stressed areas of the building panel aredeveloped at a common thickness of the fiber reinforced polymericmaterial, with no overlap of excess material anywhere in any of theouter layer structure, the inner layer structure or the reinforcingmembers structure, resulting in an efficient use of materials andstructure.

In another embodiment, not shown, all of the elements shown in FIG. 37are assembled in the mold dry, namely without addition of any resin intothe mold before the mold is closed. Resin is then infused into the moldafter the mold is closed and as the air is being evacuated from themold. Such process is known as an infusion process, which is also anacceptable process for making building panels of the invention.

FIG. 39 shows a side elevation view of a portion of a building panel 14of the invention, as viewed looking toward outer layer 36. The outerlayer 36 and inner layer 34 are fiberglass reinforced polymeric layerssuch as are described with respect to FIGS. 6 and 8. The structurallyreinforcing bridging member 250 is configured in the shape of ahoneycomb structure wherein each wall of the honeycomb spans thethickness of the building panel between outer layer 36 and inner layer34. The walls 250 of the honeycomb structure thus serve as straight-linereinforcing members between inner and outer layers 34, 36, and providestrength and rigidity as the structurally-reinforcing members of thebuilding panel.

The dimensions of the honeycomb cells, as well as the thicknesses of thewalls 250 of the cells, can be designed for the desired, anticipated,vertical and horizontal loadings. The dimension “T3” across thehoneycomb cell is typically between about 0.25 inch and about 2 inches.The thickness of a bridging member 250 is typically about 0.02 inch toabout 0.20 inch. Cell size and bridging member thickness have knownrelationships which can be used by those skilled in the art to designhoneycomb building panels having desired structural strengthcharacteristics.

The honeycomb structure illustrated in FIG. 39 is genericallyrepresentative of a family of building panels which have both upstandingstructurally-reinforcing members 50 and transversely-extendingstructurally-reinforcing members. The transversely-extendingstructurally-reinforcing members extend between, and are optionallyconnected to, the upstanding ones of the structurally-reinforcingmembers. The combination of the upstanding structurally-reinforcingmembers and the transversely-extending structurally-reinforcing memberscan define regular or irregular, open or closed, geometric shapes, whichoptionally extend generally continuously between inner layer 34 andouter layer 36. FIG. 39 illustrates a regular hexagon as an example ofregular geometric shapes.

Studs 123 can be used as optional, for example to create a cavity 131for running utilities or to receive a batt of fiberglass insulation, orto further contribute to the strength of the building panel.

The building panels illustrated in FIGS. 30-34 can employ top plates 20and bottom plates 16 in the same manner described with respect to theembodiments illustrated in e.g. FIGS. 8 and 9.

Throughout this teaching, fiber-reinforced studs 123 have beenillustrated and taught as having an end panel 130, first and second legs128, and outwardly-extending flanges 126. See, for example, FIG. 8. Theinvention further contemplates studs 123 structured as closedstructures, such as a closed-perimeter rectangular tube, optionallydevoid of flanges 126. The invention further contemplates a stud 123 asa pultruded structure, in both the illustrated flange cross-section andthe closed-perimeter cross-section.

Studs 123 can be located over a structurally-reinforcing member 50, 209,250, as at 123A in FIG. 31, or away from the structurally-reinforcingmember as illustrated in FIG. 33.

Among the requirements of the structurally-reinforcing member is thatthe materials in the structurally-reinforcing member cannot be sensitiveto, susceptible to substantial degradation by, water or any inclusionscommonly found in water, whether dissolved minerals or organic materialssuch as life forms which live on or transform the compositions of thefibers. Namely, the materials cannot be susceptible to degradation bywater or anything in water, to the extent such degradation jeopardizesthe ability of the structure made from such building panels, to providethe compressive strength necessary to support the overlying buildingloads, and the bending loads imposed by subterranean forces, andabove-grade weather forces.

Accordingly, the structurally-reinforcing member typically does notinclude uncoated corrugated wood fiber structures commonly referred toas corrugated cardboard structures, or any other fibers whose strengthsare substantially affected by moisture or moisture vapor, or anyinclusions which can be expected to occur in moisture found in or aroundthe soil adjacent a building structure. Further, the fibers cannot besusceptible to insect infestation, or any other degrading factors. Thus,the fibers are inert inorganic materials such as are illustratedelsewhere herein.

In the alternative, susceptible fibers can be used where such fibers arecombined with sufficient coating of e.g. a resin to preclude suchdeleterious elements from reaching the fibers over the expected use lifeof the building panel; or where one or more layers disposed outwardly ofa fiber layer in the panel is capable of preventing enough moisture fromgetting to the fibers that the fibers can become degraded as a result ofexposure to moisture.

In any of the embodiments of the invention, one or more gel coats can beapplied to the panel structure at one or both of the inner and outersurfaces.

Whatever the materials used for the reinforcing fiber, the foam, and theresin, all of such elements, including UV inhibitors and fire retardantadditives, are chemically and physically compatible with all otherelements with which they will be in contact, such that no deleteriouschemical or physical reaction takes place in wall systems of theinvention.

One of the substantial benefits of wall structures made using theteachings of the invention is that the wall structures are water-proofand moisture proof. For example, in areas where hurricanes are frequent,building codes require concrete structure in above-grade housing walls.Experience has shown that hurricane-force winds drive rain forcefullythrough such concrete wall structures so as to cause substantial waterdamage even when the building structure, itself, is not damaged.

By contrast, wall structures of the invention are essentially waterproof; and such water proof characteristic is not affected byhurricane-driven rain. Layer 36 is, itself, water proof. While layer 36is quite tough for water to penetrate, even if outer layer 36 isbreached, the foam blocks 32 are water proof in that the individualcells of the foam blocks 32 are closed cells. If the foam layer is alsobreached, inner layer 34 is also water proof. In addition, where aweaving layer is used, before the breaching force reaches layer 34, ithas to pass through weaving layer 50, which is another tough andwaterproof layer, whether layer 50 is encountered adjacent layer 36 oradjacent layer 34. In any event, any breaching force has to penetratemultiple waterproof layers, at least two of which are substantiallytough layers when considered in light of the types of forces which aretypically imposed on buildings by weather or other typical outsideloads. The structures which do not include foam are similarly-effectivebarriers to water penetration.

Regarding the joint between the bottom of the wall panel and the bottomplate, such joint can be filled with curable resin, adhesive, caulk, orother barrier material, thus to positively block any penetration ofwater at the joint between the wall panel and the bottom plate.

Similarly, vertical joints in the foundation wall using e.g. “H”brackets 146 can be closed to water penetration by applying curableresin, adhesive, caulk, or other water-proofing coatings to the joint.In addition, as mentioned elsewhere herein, adhesives, resins, and thelike can be applied to the building panels and/or to the variousbrackets before the brackets are applied to the respective buildingpanels, thereby to provide further water-proofing characteristics to thefinished foundation wall, or above-ground wall.

Building panels of the invention find use in various residential, lightcommercial and industrial construction applications. The strength andother specifications of a given wall panel are specified in accord withthe loads to be imposed during the anticipated use life of the building.

Wall structures of the invention find application in and as, for exampleand without limitation, the construction of foundation walls; frostwalls e.g. in buildings which have no basement; manufactured home basecurtain walls; floor systems; ceiling systems, roof systems; exteriorabove-grade walls; curtain walls as in high rise construction replacingconcrete block; and exterior walls in areas that use masonry exteriors,such as in coastal construction. While the specification and drawingshave focused on foundation walls, the principles disclosed herein applyin the same way to other uses of panels and accessories of theinvention.

A variety of accessories and parts can be used with projects which usewalls of the invention, for example and without limitation, posts tosupport beams/girders, fiber-reinforced piers which optionally includestructural top and bottom, post pads, inside corner brackets, outsidecorner brackets, “H” channel brackets, top plate connectors, garagefloor shelves, support brackets, floor-and-garage apron brackets,service door cut outs, garage door cut outs, frost wall transitions, andstud profiles.

In addition, there can be mentioned fiber and resin patch kits suitablefor use to patch a damaged building panel, angled wall connectors, fullbasement wall to garage transition, frost wall returns, attachment oftop and bottom plates, along with potential shipping advantages wherethe top and bottom plates are affixed at the construction site, beampockets, post pads in the footer to distribute load, and window bucks.There can also be mentioned fasteners to apply exterior product and toprovide connections to other parts of the building. Such fasteners canbe, for example and without limitation, metal or fiber-reinforcedpolymer composite. A wide variety of accessories can be affixed to thewall structure using conventionally available adhesives for fieldapplications.

A specific advantage of wall systems of the invention is that such wallsystems can be readily sized and configured for use withalready-available standard size conventional building products, e.g.construction materials.

Building panels of the invention can be cut, using conventional toolscommonly available at a construction site, to fit the needs of the jobat hand. For example, a panel can be cut for length. A window openingcan be cut out. A door opening can be cut out. Utility perforations ofthe foundation wall can be cut, such as for furnace fresh air intake orcombustion gas exhaust, or the like, or such utilities can be run incavities 131 between studs 123 and inwardly or inner layer 34.

Advantages of the invention include, without limitation, a compositebottom plate which has potential to provide a wider footprint to theunderlying soil than the projected area of the wall panel, fordistributing the overlying weight of the building. The bottom plate canbe applied on site or off site. The wall structures of the invention arelight weight compared to the concrete structures they replace. The wallstructures of the invention are waterproof, versatile, mold resistant,termite resistant, and rot resistant. The substantial polymericcomponent of the compositions of wall structures of the inventionprovides a desired level of radon barrier in accord with existingbuilding codes whereby the conventionally-used polymeric layer on theoutside of the foundation wall is not needed, and can be omitted, alongwith corresponding savings in material and labor costs.

Typical wall structures of the invention can be installed with manuallabor, and do not require bringing any large machines to theconstruction site for the purpose of installing a footer, a foundationwall, or an above-grade wall, no form truck, no crane to install thebuilding panels.

The invention does contemplate larger wall panels, e.g. thicker, higher,and/or longer, which can weigh at least 250-750 pounds or more,whereupon a light-duty lifting device, such as a light-duty crane, isoptionally used to install such wall panels, with correspondingreduction in labor cost. Further, where a wall or roof panel is beingerected above the ground floor, a suitable-weight crane facilitates suchgreater-height installation.

Wall structures of the invention can be installed in all seasons and allweather, so long as the excavation can be dug to a suitable naturalsupport base. Panels of the invention are environmentally friendly.Panels of the invention are consistent with the requirements to qualifyas Green buildings and/or as Energy Star buildings whereby buildingsbuilt with building panels of the invention may qualify for suchratings. No damp proofing is needed. Once the foundation walls are inplace, the interior of the so-enclosed space is ready to be finished.HVAC cavities are available between studs 123. Plumbing and electric canalso be run through the walls easily, again between studs 123,optionally inside studs 123.

Additional insulation can be easily installed in the wall cavitiesbetween studs 123, thereby to achieve e.g. at least R26 insulationfactor. The building panels can be repaired more readily than concrete.Openings can be cut more easily than concrete. Wall changes can be mademore easily than concrete. Any typical wall height can be achieved. Thebuilding panels can be installed on an aggregate stone footer, wherebyno pouring of a concrete footer is required. Thus, the lowest level wallof the building can be completed with no need for any ready-mix concreteat the construction site.

Insulation property gained as part of the wall structure can be aboutR-15 without additional installation of insulation by using 3 inches ofR5 per inch foam insulation blocks 32. Additional insulation can beadded in cavity 131 to increase the thermal insulation value of thewall. In the alternative, the thermal insulation value of the wall canbe increased by increasing the thickness of the wall between the innerand outer layers, using correspondingly thicker foam blocks 32, andfilling all of the space with the foam blocks.

Wall structures of the invention have multiple desirable properties,including being fire resistant where fire retardant ingredients areincluded in the resin formulation, being a good barrier to ultravioletrays, providing good sound attenuation, being generally free from insectinfestation, being generally not susceptible to infestation byrot-generating organisms, being a good water barrier, and being a goodbarrier to transmission of radon gas.

Wall structures of the invention are sturdy, durable, and have veryfavorable expansion and contraction ratings compared to the concretethey replace. The wall structures tolerate a wide range of temperaturessuch as are encountered in building construction. The building panels ofthe invention are easy to transport to the construction site. Thebuilding panels can be mass-produced and do not have to beproject-specific like known e.g. insulated wall systems which areproduced off-site, and transported to the construction site aspre-fabricated wall systems. Wall, ceiling, roof, and floor structuresof the invention can be installed in locations where it is difficult toget delivery of ready-mix concrete, such as on islands, in weightrestricted areas, in high-rise curtain walls, and the like.

Although the invention has been described with respect to variousembodiments, it should be realized this invention is also capable of awide variety of further and other embodiments within the spirit andscope of the appended claims.

Those skilled in the art will now see that certain modifications can bemade to the apparatus and methods herein disclosed with respect to theillustrated embodiments, without departing from the spirit of theinstant invention. And while the invention has been described above withrespect to the preferred embodiments, it will be understood that theinvention is adapted to numerous rearrangements, modifications, andalterations, and all such arrangements, modifications, and alterationsare intended to be within the scope of the appended claims.

To the extent the following claims use means plus function language, itis not meant to include there, or in the instant specification, anythingnot structurally equivalent to what is shown in the embodimentsdisclosed in the specification.

1. A resin-based, fiber-reinforced polymeric structural building panel,designed and adapted to be used in constructing a building, saidbuilding panel having a height defined between a top and a bottom ofsaid building panel when said building panel is in an upright useorientation, a length, and a thickness, said structural building panelcomprising: (a) an outer fiber-reinforced polymeric layer, said outerlayer defining an outwardly-facing surface of said building panel whensaid building panel is being used in a building wall; (b) an innerfiber-reinforced polymeric layer, said inner layer defining aninwardly-facing surface (25, 57) of said building panel when saidbuilding panel is being used in a building wall; and (c) a plurality ofstructurally-reinforcing members extending between the top and thebottom of said building panel, and extending between locations at orproximate said outer layer and locations at or proximate said innerlayer; said building panel further comprising (d) at least one of (i) atop plate, or (ii) a bottom plate, or (iii) a plurality of studs (23,123, 223, 323) extending inwardly of the inwardly-facing surface (25),or (iv) rigid insulating foam elements extending between, and being insurface-to-surface contact with, respective ones of saidstructurally-reinforcing members, said inner layer, and said outerlayer, or (v) said one or more structurally-reinforcing memberscomprising fiber-reinforced polymeric members, or (vi) said buildingpanel, in an upright use orientation, having a top-to-bottom crushresistance capacity of at least about 4000 pounds per lineal foot.
 2. Abuilding panel as in claim 1 wherein said inner layer and said outerlayer comprise resin-impregnated fiberglass layers.
 3. A building panelas in claim 2, said building panel further comprising at least one of awood top plate and a fiber-reinforced polymeric bottom plate, optionallya pultruded bottom plate and wherein such bottom plate is at least about0.18 inch thick.
 4. A building panel as in claim 1, said building panelhaving a vertical crush resistance of at least 6000 pounds per linealfoot.
 5. A building panel as in claim 1, said building panel having apoint horizontal loading bending moment resistance of at least aboutpounds per square foot between the top and the bottom.
 6. A buildingpanel as in claim 1 wherein said inner layer, said outer layer, and saidstructurally reinforcing members comprise fiber-reinforced polymericstructures, said building panel comprising a plurality of studs (123,223, 323), spaced from each other along the length of said buildingpanel and extending generally between the top and the bottom, said studsextending, away from said inner layer and away from said outer layer ina common direction.
 7. A building panel as in claim 1, said buildingpanel comprising a top plate, a pultruded bottom plate, and a pluralityof studs (123, 223, 323) extending inwardly from the inwardly-facingsurface (25) and away from said outer layer, said studs being arrangedgenerally parallel to each other and being spaced from each other, andextending from the inwardly-facing surface (25) a distance of about 1inch to about 6 inches.
 8. A building panel as in claim 7, said buildingpanel comprising rigid insulating foam elements extending between, andbeing in surface-to-surface contact with, respective ones of saidstructurally-reinforcing members.
 9. A building panel as in claim 1,said reinforcing members being comprised in a weaving layer which weavesback and forth, as said structurally-reinforcing members, at crossingswhich extend across a distance which separates said inner layer and saidouter layer, the crossings being spaced along the length of saidbuilding panel, said weaving layer extending along at least one of saidinner layer and said outer layer between said crossings, and whereinfirst portions of said weaving layer form unitary structural elementswith second portions of at least one of said inner layer and said outerlayer between the spaced crossings.
 10. A building panel as in claim 1wherein said inner layer forms a unitary structural element incombination with portions of said structurally reinforcing members. 11.A building panel as in claim 2 wherein at least one of said inner layerand said outer layer has a nominal thickness between about 0.03 inchthick and about 0.15 inch thick.
 12. A building panel as in claim 9wherein the crossings of said weaving layer are spaced from each other,along the length of said building panel, at distances of about 4 inchesto about 24 inches.
 13. A building panel as in claim 1, furthercomprising anchor brackets (24) associated with at least one of the topof said building panel and the bottom of said building panel, saidanchor brackets supporting a top plate and/or a bottom plate from saidinner layer.
 14. A building panel as in claim 1, further comprising atleast one of a bottom plate mounted to the bottom of said building paneland a top plate mounted to the top of said building panel.
 15. Abuilding panel as in claim 1, further comprising a support bracketmounted to said building panel in association with the top of saidbuilding panel, said support bracket comprising a floor support paneladapted to support an edge of a floor adjacent said building panel,which edge overlies said floor support panel, and a brick support paneladapted to support bricks as an outwardly disposed layer on a buildingin which said support bracket is used.
 16. A building panel as in claim1, further comprising rigid insulating elements of closed cell foamhaving densities of about 1 pound per cubic foot to about 12 pounds percubic foot.
 17. A building panel as in claim 1, further comprising rigidinsulating elements of closed cell foam having densities of about 2pounds per cubic foot to about 8 pounds per cubic foot, filling spacesbetween said inner layer and said outer layer, and between respectiveones of said structurally-reinforcing members.
 18. A building panel asin claim 1 wherein at least one of said inner layer and said outer layercomprises portions of multiple layer elements which overlap each otherin, at least in part, defining the respective said inner layer or therespective said outer layer.
 19. A building panel as in claim 1, saidone or more structurally-reinforcing members comprising upstandingstructurally-reinforcing members when said building panel is in anupright orientation, further comprising transversely-extendingstructurally-reinforcing members extending between ones of saidupstanding structurally-reinforcing members.
 20. A building panel as inclaim 19 wherein said transversely-extending structurally-reinforcingmembers and said upstanding structurally-reinforcing memberscollectively define regular closed geometric shapes, which extendgenerally continuously between said inner layer and said outer layer.21. A building panel as in claim 8 wherein said inner layer, said outerlayer, and said structurally-reinforcing members are defined by aplurality of fiber-reinforced layer elements (200) and wherein a givenlayer element (200) extends (i) from a first end thereof adjacent afirst outwardly-facing side of a first said insulating foam elementalong an outwardly-facing surface of a second insulating foam element toa second side (206) of the second insulating foam element, (ii) betweenthe second side (206) of the second insulating foam element and a firstside (208) of a third insulating foam element to inwardly-facing sides(210) of the second and third insulating foam elements, and (iii) alongthe inwardly-facing side (210) of the third insulating foam element toan inwardly-facing side of a fourth insulating foam element, and to asecond end of the given layer element adjacent the inwardly-facing sideof the fourth insulating foam element.
 22. A resin-based,fiber-reinforced composite structural building panel, having a heightdefined when said building panel is in an upright use orientation, alength, and a thickness, said structural building panel comprising: (a)an outer fiber-reinforced polymeric layer, said outer layer defining anoutwardly facing surface of said building panel when said building panelis being used in a building wall; (b) an inner fiber-reinforcedpolymeric layer, said inner layer defining an inwardly-facing surface(25) of said building panel when said building panel is being used in abuilding wall, said inner layer and said outer layer defining a generalthickness (T) of said building panel; (c) a plurality ofstructurally-reinforcing members extending between the top and thebottom of said structural building panel, and extending from locationsat or proximate said outer layer to locations at or proximate said innerlayer; (d) rigid insulating foam elements in said structural buildingpanel, extending between, and being in surface-to-surface contact with,respective ones of said structurally reinforcing members; and (e)reinforcing studs between said rigid insulating foam elements and saidinner layer, said reinforcing studs being so dimensioned that thethickness of said building panel at said reinforcing studs extendsinwardly, as into a building in which said building panel is installed,from the innermost extent of the general thickness (T).
 23. Aresin-based fiber-reinforced composite structural building panel, havinga height defined when said building panel is in an upright useorientation, a length, and a thickness, said structural building panelcomprising: (a) an outer fiber-reinforced polymeric layer, said outerlayer defining an outwardly-facing surface of said building panel whensaid building panel is being used in a building wall; (b) an innerfiber-reinforced polymeric layer, said inner layer defining aninwardly-facing surface (25, 57) of said building panel when saidbuilding panel is being used in a building wall; (c) rigid insulatingfoam elements in said structural building panel, (i) a first set of saidfoam elements having lengths thereof extending along the height of saidbuilding panel, widths thereof extending along the length of saidbuilding panel, and thicknesses thereof, less than the respectivewidths, extending along the thickness of said building panel, (ii) asecond set of said foam elements having lengths thereof extending alongthe height of said building panel, widths thereof extending along thethickness of said building panel, and thicknesses thereof, less than therespective widths, extending along the length of said building panel,the widths of the second set of said foam elements being greater thanthe thickness of the first set of said foam elements, ones of saidsecond set of said foam elements being spaced from each other by ones ofsaid first set of said foam elements.
 24. A resin-based,fiber-reinforced composite structural building panel as in claim 23wherein said inner layer extends over inner surfaces of said first setof said foam elements and over inner surfaces of said second set of foamelements such that both the first set of foam elements and the secondset of foam elements are disposed between said inner layer and saidouter layer.
 25. A resin-based, fiber-reinforced composite structuralbuilding panel as in claim 23 wherein said inner layer extends inwardlyinto such building, from adjacent a foam element of the first set to aninner-most portion of a foam element of the second set, a distance ofabout 3 inches to about 6 inches.
 26. A resin-based, fiber-reinforcedcomposite structural building panel as in claim 23, foam elements of atleast one of said first and second sets of foam elements being wrappedin resin-impregnated fibrous layers.
 27. A resin-based, fiber-reinforcedcomposite structural building panel as in claim 26 wherein said wrappinglayers have nominal thicknesses of between about 0.03 inch thick andabout 0.15 inch thick.
 28. A resin-based, fiber-reinforced compositestructural building panel as in claim 23 wherein said foam elementscomprise closed cell foam having densities of about 1 pound per cubicfoot to about 12 pounds per cubic foot.
 29. A resin-based,fiber-reinforced polymeric composite structural building panel designedand adapted to be used in constructing a building, said building panelhaving a height defined between a top and a bottom of said buildingpanel when said building panel is in upright use orientation, a length,and a thickness, said structural building panel comprising afiber-reinforced pultruded structure, said pultruded structurecomprising: (a) an outer fiber-reinforced polymeric layer (236) definingan outwardly-facing surface of said building panel when said buildingpanel is being used in a load-bearing building wall; (b) an innerfiber-reinforced polymeric layer (234) defining an inwardly-facingsurface (25) of said building panel when said building panel is beingused in a load-bearing building wall; and (c) a plurality of bridgingmembers (250) spaced along the length of said building panel andbridging between said inner layer and said outer layer, said buildingpanel in upright use orientation having a vertical crush resistancecapacity of at least about 2000 pounds per lineal foot length of saidbuilding panel.
 30. A structural building panel as in claim 29, furthercomprising a plurality of studs extending inwardly from the innersurface (25) and away from said outer layer, between the top and thebottom of said building panel, said studs being spaced from each otheralong the length of said building panel.
 31. A structural building panelas in claim 29, further comprising a top plate at the top of saidbuilding panel and a bottom plate at the bottom of said building panel.32. A structural building panel as in claim 30 wherein said studs areintegral elements of said pultruded structure.
 33. A structural buildingpanel as in claim 29 wherein said building panel has a vertical crushresistance capacity of at least of at least about 4000 pounds per linealfoot length and a point horizontal bending resistance of at least about155 pounds per square foot between the top and the bottom of saidbuilding panel.
 34. A resin-based, fiber-reinforced polymeric compositestructural building panel designed and adapted to be used inconstructing a building, said building panel having a height definedbetween a top and a bottom of said building panel when said buildingpanel is in an upright orientation, a length, and a thickness, saidstructural building panel comprising: (a) a first set offiber-reinforced pultruded blocks having lengths thereof extending alongthe height of said building panel, widths of said first set of blocksextending along the length of said building panel, and thicknesses ofsaid first set of blocks, being less than the respective widths,extending along the thickness of said building panel; (b) a second setof fiber-reinforced pultruded blocks having end walls (126, 130), andlegs (128) extending between said end walls, and lengths of saidpultruded blocks extending along the height of said building panel,widths of said second set of blocks extending along the thickness ofsaid building panel, and thicknesses of said second set of blocks, lessthan the respective widths of said second set of blocks, extending alongthe length of said building panel, the widths of the second set of saidpultruded blocks being greater than the thicknesses of said first set ofsaid pultruded blocks, ones of said second set of said pultruded blocksbeing spaced from each other by ones of said first set of pultrudedblocks, said pultruded blocks of said first and second sets of pultrudedblocks being in abutting relationship with each other and defining agenerally continuous outer surface (56) of such assemblage of suchpultruded blocks, and an inner surface (57) of such assemblage of suchpultruded blocks: and (c) an outer fiber-reinforced polymeric layer (36)mounted to, or adjacent, said first and second sets of pultruded blocksat or adjacent the generally continuous outer surface, so as to bridgebetween respective ones of said pultruded blocks.
 35. A structuralbuilding panel as in claim 34 wherein said building panel, in an uprightuse orientation, has a vertical crush resistance capacity of at leastabout 4000 pounds per lineal foot length of said building panel.
 36. Astructural building panel as in claim 34, further comprising a top plateat the top of said building panel and a bottom plate at the bottom ofsaid building panel.
 37. A structural building panel as in claim 34,said pultruded blocks of said second set comprising a reinforcing web(238) displaced from both said end walls (126, 130) and extendingbetween said first and second legs.
 38. A structural building panel asin claim 35, further comprising an inner fiber-reinforced polymericlayer mounted over said first and second sets of pultruded blocks so asto consolidate said pultruded blocks of said first and second sets toeach other at the inner surface of said building panel.